Interior rearview mirror system for a vehicle

ABSTRACT

A vehicular interior rearview mirror system includes an interior rearview mirror assembly having one of (a) a variable reflectance reflective element and (b) a prismatic reflective element. The interior rearview mirror assembly includes an information display disposed behind and viewable through the reflective element. The interior rearview mirror assembly includes a video camera having, when the interior rearview mirror assembly is normally mounted in the vehicle, a field of view that encompasses one of (i) the windshield of the vehicle and (ii) the driver of the vehicle. The interior rearview mirror assembly may include other electrical accessories such as, for example, a light, a rolling code garage door opener, and a microphone.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 12/339,786,filed Dec. 19, 2008 (Attorney Docket DON01 P-1494), which is acontinuation of U.S. patent application Ser. No. 11/935,808, filed Nov.6, 2007, now U.S. Pat. No. 7,467,883, which is a continuation of U.S.patent application Ser. No. 11/835,088, filed Aug. 7, 2007, now U.S.Pat. No. 7,311,428, which is a continuation of U.S. patent applicationSer. No. 11/498,663, filed Aug. 3, 2006, now U.S. Pat. No. 7,255,465,which is a continuation of U.S. patent application Ser. No. 11/064,294,filed Feb. 23, 2005, now U.S. Pat. No. 7,108,409, which is acontinuation of U.S. patent application Ser. No. 10/739,766, filed Dec.18, 2003, now U.S. Pat. No. 6,877,888, which is a continuation of U.S.patent application Ser. No. 10/134,775, filed Apr. 29, 2002, now U.S.Pat. No. 6,672,744, which is a continuation of U.S. patent applicationSer. No. 09/526,151 filed Mar. 15, 2000, now U.S. Pat. No. 6,386,742,which is a division of U.S. patent application Ser. No. 08/918,772,filed Aug. 25, 1997, now U.S. Pat. No. 6,124,886, the disclosures ofwhich are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

This invention relates to rearview mirrors for vehicles and, moreparticularly, to an improved, modular rearview mirror assemblyincorporating electrical components such as lamps and switches withinthe assembly for illumination of various portions of the vehicleinterior, displays or other instruments of various types all of whichare mounted and assembled via an integrated carrier member.

Prior rearview mirror assemblies for vehicles incorporating lampassemblies with map or reading lights, switches, or otherinstrumentation such as compasses, light sensors and controls therefor,while functioning well for their intended purposes, have been relativelycomplicated, involved and expensive to manufacture on a high volumebasis. More specifically, many operations have been necessary toproperly assemble the various parts in a rearview mirror housing or casehaving such additional features to arrive at the desired product. Thesevarious parts have, in many cases, been difficult and tedious to handleand position requiring high intensity, expensive manual labor which hasprevented the cost of such assemblies from being reduced.

For example, in the lighted rearview mirror assembly of U.S. Pat. Nos.4,733,336 and/or 5,178,448, a molded plastic case is provided with aday/night toggle actuator and a support arm for mounting the assembly ona windshield mounted button, header support or the like. In order tomanufacture that assembly, the day/night toggle actuator and support armmust be mounted within the case followed by insertion of appropriatereflector housings, and a wire harness/assembly incorporating a plugreceptacle for mounting on the mirror housing, appropriate lamp or bulbholders, and appropriate switches, all of which must be inserted andmounted within the case. The wire harness/assembly itself requiresseparate assembly prior to insertion in the mirror housing so as toincorporate the necessary switches, bulb holders, plug connection andsoldered or clip-type wire joints. These many connections and handlingrequirements create numerous possibilities for failure and improperwiring. In addition, the above assembly procedures have requiredextraordinary amounts of assembly time and manual labor, thereby drivingup or preventing reductions in the cost of such assemblies.

The above assembly procedures have also restricted and/or prevented useof certain types of rearview mirror housings or cases. For example, theuse of molded, polymeric rearview mirror housings in which a prismaticmirror element is snapped in place after molding of the housing andwhile the housing was still in a warm, somewhat soft and pliable statewas very difficult because of the required assembly time for insertingthe lamps, reflectors, bulb holders, plug connections, switches, wiringharnesses and the like, all before insertion of the reflective prism insufficient time to allow a shrink fit of the minor case around the minorelement.

In addition, prior commercially successful lighted mirrors formed fromresinous plastic materials have also typically required the use oftemperature resistant, high heat deflection temperature resins in orderto withstand the high levels of heat generated therewithin by the lampsand other electrical components. Such temperature resistant resins arehigher in cost making such assemblies more expensive.

Accordingly, an improved rearview mirror assembly for vehiclesincorporating lamp assemblies or other electrical components such asinstrumentation or controls, and an improved manufacturing method wasdesired for simplified assembly, increased reliability, increased heatmanagement, reduction in assembly time, and flexibility for use withdifferent types and styles of mirror housings and cases.

SUMMARY OF THE INVENTION

The present invention provides an improved modular rearview mirrorassembly for vehicles incorporating lamps or other electricalcomponents, instrumentation and/or controls which provides an economicalassembly useful with many different mirror case shapes and housingstyles with resultant increased durability and reliability, improvedheat management, as well as reduced manufacturing complexity and time.In addition, an improved manufacturing method for making such modularrearview mirror assemblies is also provided.

In one aspect, the invention provides a modular rearview mirror assemblyfor vehicles including a case for supporting a mirror element, the casehaving at least one opening therethrough, a reflective mirror elementsupported and retained by the case, and a support on the assembly formounting the assembly on a vehicle. A modular carrier member is formedseparately from and mounted on the case. The carrier member includes anelectrically conductive circuit member and a support body. The circuitmember is formed separately from and secured to the support body, andprovides an integral support, electrical connections for, and anelectrical distribution network to at least one lamp on the case. A lampis mounted on the carrier and connected to the circuit member and isadapted to provide light through the case opening to a portion of thevehicle when the mirror assembly is mounted therein.

In another aspect of the invention, the invention provides a modularrearview mirror assembly for vehicles including a mirror case,reflective mirror element, support for mounting the assembly on avehicle and a modular carrier member all as set forth above. In thisaspect of the invention, however, the carrier member provides anintegral support, electrical connections for, and an electricaldistribution network to at least one electrical component on the case.The case includes an electrical component mounted on the carrier member,which component is connected to the circuit member for operation on themirror assembly. In a preferred form of this aspect of the invention,the carrier member also includes an electrical switch connected to thecircuit member for controlling operation of the electrical component.Preferably, that switch is accessible for operation at the exteriorsurface of the mirror case.

Other preferred features of the invention include the provision of areflector for reflecting light from the lamp through the case openingfor illuminating portions of the interior of the vehicle such as thedriver seating area, passenger seating area or both. The carrier membermay also include an electrical switch, and a lens over the lightopening. In preferred forms of the invention, a pair of lamps andopenings through the mirror case are provided, each having a reflectorand electrical switch for controlling same, as well as a lens over theopening.

The invention may be used with various types of rearview mirror casessuch as those using a preformed bezel for retaining the mirror elementwithin the case, the electrical switches for the lamps being accessiblethrough the front of such bezel. Alternately, this invention makescommercially possible the molding of a one-piece mirror housing where apreformed, premolded lip is formed in one-piece on a molded resinousmirror case to allow snap-in insertion of a mirror element while thecase is still warm and flexible and wherein the electrical switches forcontrolling the lamps are accessible from the bottom of the mirrorassembly. Such one-piece housings are preferably made from polyolefinresins such as polypropylene or polypropylene/polyethylene copolymershaving lower heat deflection temperatures, higher material shrinkagerates, and lower cost. A plug connection to a power source external ofthe mirror assembly may also be provided for access through an openingin the case. Mirror cases for both interior and exterior use on avehicle are also contemplated.

In a preferred form, the circuit member of the present invention ispreferably integrally molded to be at least partially encapsulatedand/or encased within a resinous, polymeric support body preferably byinsert molding to form the carrier member such that various sets ofelectrical connections extend from the molded body for connection toswitches, light bulbs or other electrical components. The reflectorsused with the lamps in the invention may be separately molded withmetalized reflective surfaces and removably mounted to the carriermember in alignment with the lamp or light bulb, or may be formed frommetal and inserted in an appropriate receptacle in the carrier member.Both regular and compound parabolic reflector shapes are contemplated.

In another preferred form of the invention, the carrier member mayprovide a single lamp and reflector which illuminates both the driverand passenger seating areas in the front of the vehicle. In this form,the carrier member includes a lamp or light bulb, reflector, switch,integral circuit member and plug receptacle for connection to anexternal power source all in a single unit which may be removablyinserted from the exterior of the case, either before or after mountingof the reflective mirror element. This form allows repair and servicingof the lamp and carrier member following manufacture.

In yet another preferred form of the invention, the carrier memberincludes an edge portion defining a recess while the circuit memberincludes a bulb holder within the recess. A reflector is secured to thecarrier member and received in the recess. The recess edge portionengages and supports the reflector while the lamp includes a bulbmounted within the recess. The reflector reflects light from the bulbthrough the case opening. This form of the invention allows thereflectors to be interchanged and selected depending on the positioningof the light to be provided by the rearview mirror assembly anddepending, for example, on whether the vehicle in which the mirrorassembly is installed is designed for left or right hand drive.

In other forms of the invention, the rearview mirror assembly mayinclude a prismatic reflective mirror element and a day/night actuatormounted for movement between day and night positions on the case tomodify the amount light reflected by the mirror element to the eye ofthe viewer. In this form, the carrier member includes a stop area forengaging the actuator in one of the day and night positions to limitmovement of the day/night actuator. Preferably, the day/night actuatoris pivotally mounted on an internal wall which includes a second stoparea for engaging the actuator in the other of the day and nightpositions to limit movement of the actuator in that position.

In addition, the case may include internal, reinforcing walls eachincluding slots receiving a portion of the carrier member to secure thecarrier member within the case. In this form, the carrier member mayinclude recessed caroming surfaces for facilitating insertion of thecarrier member into the slotted internal walls.

Further, in yet other forms of the invention, the carrier member mayinclude a plug connection for receiving an electrical plug to connectthe circuit member to an external power source and a latch memberadapted to engage the plug when connected to the plug connection toretain the plug in the plug connection.

In addition, the carrier member may include a diode connected to thecircuit member for reducing current leakage and battery drain when theassembly is connected to the electrical system of a vehicle.

In yet another aspect of the invention, a method for assembling amodular rearview mirror for vehicles includes the steps of providing amirror case for supporting a reflective mirror element and a lamp forilluminating a portion of a vehicle, forming a modular carrier member bysecuring a separate electrically conductive circuit member to anon-electrically conductive, insulating support body, forming asubassembly by connecting the lamp to the modular carrier member toprovide both support and electrical connections for the lamp, mountingthe modular carrier member and lamp subassembly on the mirror case suchthat the lamp is in registry with an opening in the case, and mounting areflective mirror element on the mirror case such that the modularcarrier member is concealed on the mirror case while the lamp ispositioned to provide illumination through the opening in the case whenthe rearview mirror is mounted on a vehicle. The carrier member ispreferably molded using any of injection molding, compression molding,extrusion molding, reaction injection molding or casting. The carriermember may also be formed in two sections which are fastened together atleast partially around the circuit member, or by forming the supportbody and attaching the preformed circuit member to at least one surfaceof the support body.

Accordingly, the present invention provides simplified assembly oflighted and other rearview mirror assemblies having electricalcomponents therein by incorporating a separately formed carrier memberproviding an integrated subassembly module which allows the docking andassembly of differing reflectors, bulbs, switches, external electricalconnectors, or other electrical components to adapt use of the board todiffering mirror case shapes and housings. The carrier member is easy tograsp and install and avoids tangling, breaking and disconnection ofindividual wires as in previously known wire harness assemblies. Thecarrier member will receive differing reflectors for different vehiclesto provide different illumination areas and angles, can be provided withreceptacles for receipt of integrated circuit boards, allows the use ofintegral molding of switch bodies therein, and is easily adapted for usewith either two-piece bezel-type or one-piece, snap-in, molded mirrorcases and housings. The reflectors are highly efficient and reduce heatgenerated in the assembly by allowing use of less powerful lamps which,in turn, allows use of lower heat deflection temperature resins whichare cheaper and provide one-piece molding capabilities. The carriermember can also be molded in different configurations for each specifictype of vehicle so as to mount lamps or light bulbs at particular anglesand positions required for each vehicle. The carrier member also allowsassembly within differing mirror housings to provide differentvariations in mirror styling while also providing increased utility,especially using slotted internal walls which firmly secure the carriermember against vibration and movement within the mirror housing or case.In addition, when mounted in a day/night rearview mirror assembly usinga toggle actuator, the carrier member provides a strengthening member orreinforcement to maintain the toggle actuator in place in the event ofimpact from airbag inflation, and may also serve as a stop for limitingmovement of the actuator to one of its day or night positions. Also, theinvention provides for latching a plug connection to the circuit member,and the use of a diode on the circuit member to reduce battery drainfrom the vehicle electrical system.

These and other objects, advantages, purposes and features of theinvention will become more apparent from a study of the followingdescription taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded, perspective view of a first embodiment of themodular rearview mirror assembly for vehicles of the present invention;

FIG. 2 is a sectional end elevation of the mirror assembly of FIG. 1taken along line of FIG. 2;

FIG. 3 is a perspective view of a preferred form of the carrier memberfor use in the mirror assembly of FIGS. 1 and 2;

FIG. 4 is an exploded, perspective view of a preferred form of a stampedmetal electrical circuit adapted for insert molding within the carriermember of FIG. 3 and illustrating plug-in attachment of preferredplunger switches thereto;

FIG. 5 is an exploded, perspective view of the carrier member of FIG. 3incorporating light bulbs and reflectors for same;

FIG. 6 is a front elevation of the carrier member of FIGS. 3 and 5 fromthe side opposite that shown in those figures;

FIG. 7 is a bottom plan view of the carrier member assembly shown inFIG. 5;

FIG. 8 is an end elevation of the carrier member assembly showing amethod for attachment of a reflector to the carrier member;

FIG. 9 is a sectional end elevation of the carrier member assembly takenalong plane IX-IX of FIG. 6;

FIG. 10 is a rear elevation of the mirror assembly of FIGS. 1 and 2broken away to show the carrier member assembly within the mirrorhousing/ease and illustrating illumination from the lamp assemblies onthe carrier member;

FIG. 11 is a side elevation of a reflector for use with the carriermember of FIG. 3;

FIG. 12 is an end elevation of the reflector of FIG. 11;

FIG. 13 is a top plan view of the reflector of FIGS. 11 and 12;

FIG. 14 is a sectional side view of the reflector taken along planeXIV-XIV of FIG. 12;

FIG. 15 is a bottom plan view of a lens element for use in the presentinvention;

FIG. 16 is an end elevation of the lens of FIG. 15;

FIG. 17 is a side elevation of the lens of FIG. 15;

FIG. 18 is an exploded, perspective view of a second embodiment of themodular rearview assembly of the present invention;

FIG. 19 is a sectional side elevation of the rearview mirror assembly ofFIG. 18 taken along line XIX-XIX of FIG. 18;

FIG. 20 is a perspective view of a preferred form of the carrier memberfor use in the mirror assembly of FIGS. 18 and 19;

FIG. 21 is an exploded, perspective view of a metal stamping forinclusion in the carrier member of FIG. 20 also illustrating a preferredform of switch adapted to mate with the electrical circuit;

FIG. 22 is a front elevation of a third embodiment of the modularrearview mirror assembly of the present invention with a portion of theprismatic mirror element removed;

FIG. 23 is a fragmentary, front elevation, shown partially in section,of the mirror assembly of FIG. 22;

FIG. 24 is an exploded, front elevation of the mirror assembly of FIGS.22 and 23;

FIG. 25 is a top plan view of a preferred form of the carrier memberadapted for use with the mirror assembly of FIGS. 22-24;

FIG. 26 is an end elevation of the carrier member of FIG. 25;

FIG. 27 is a bottom plan view of the carrier member of FIGS. 25 and 26;

FIG. 28 is a perspective view of a stamped metal electrical circuitadapted for incorporation in the carrier member shown in FIGS. 25-27;

FIG. 29 is a rear elevation of the mirror assembly of FIGS. 22-24;

FIG. 30 is a sectional end elevation of a fourth embodiment of themodular review mirror;

FIG. 31 is an enlarged, fragmentary, sectional view of area XXXI of FIG.31;

FIG. 32 is an exploded, perspective view of a fifth embodiment of themodular rearview mirror assembly for vehicles of the present invention;

FIG. 33 is a rear perspective view of the mirror housing/case for theassembly of FIG. 32;

FIG. 34 is a plan view of one of the lenses used in the assembly of FIG.32 showing the exterior surface thereof;

FIG. 35 is a perspective view of the interior side of the lens shown inFIG. 34;

FIG. 36 is a fragmentary, perspective view of the rear and bottom of themirror assembly of FIG. 32 illustrating the electrical plug connectionfrom the vehicle electrical system inserted in the mirror assembly;

FIG. 37 is an exploded, perspective view illustrating the forward sideof the circuit member of the mirror assembly of FIG. 32 prior toencapsulation in the carrier member along with the preferred switchesand a diode for mounting on the circuit member;

FIG. 38 is a perspective view of the rear side of the circuit member ofthe mirror assembly of FIG. 32 illustrating the mounting of a plugconnector from a vehicle electrical system;

FIG. 39 is a perspective view of the carrier member of the mirrorassembly of FIG. 32 showing the forward side which faces the reflectivemirror element with portions of one of the reflector housings brokenaway to reveal the mounting of a bulb therein;

FIG. 40 is a perspective view of the carrier member shown in FIG. 39showing the rear side and illustrating the mounting of a plug connectorfrom a vehicle electrical system;

FIGS. 41 and 42 are fragmentary, perspective views of the carrier membershown in FIG. 40 illustrating the mounting of the plug connector fromthe vehicle electrical system;

FIG. 43 is a sectional elevation of the mirror assembly taken alongplane XLIII-XLIII of FIG. 32;

FIG. 44 is a sectional elevation of the mirror assembly taken alongplane XLIV-XLIV of FIG. 32;

FIG. 45 is a sectional elevation of the mirror assembly taken alongplane XLV-XLV of FIG. 32;

FIG. 46 is a sectional elevation of the mirror assembly taken alongplane XLVI-XLVI of FIG. 32; and

FIG. 47 is a fragmentary sectional elevation of a sixth embodiment ofthe modular rearview mirror assembly for vehicles of the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawing figures in greater detail, the terms “top,”“bottom,” “front,” “back,” “rear,” “forward,” “horizontal” and“vertical” are used for reference purposes only and are not intended tolimit the scope of protection for the invention.

FIGS. 1-17 illustrate a first embodiment 10 of the modular rearviewmirror assembly of the present invention including a molded, resinousplastic mirror housing having a case 12 and a mirror element retainingbezel 18, a reflective mirror element 14, a resinous, polymeric,shatterproofing layer 16 applied to the rear surface of the reflectiveelement 14, and a modular carrier member or integrated subassemblymodule 20 which, as is more fully explained below, is mounted within thehollow interior of molded case 12 prior to fitting of the reflectivemirror element 14. Carrier member 20 provides an integral support,electrical connections, and an electrical distribution network for oneor more electrical components used within mirror assembly 10 such as alamp or light bulb 130, electrical switches 72 for controlling the lampor light bulb, a plug connection 92 for connecting the carrier member orsubassembly to an external power source, or a receptacle for a printedcircuit board which could be used for control and operation ofinstrumentation, information readouts or other electronic devices withinthe vehicle. Carrier member 20 also receives and mounts reflectors 110,112 adapted to direct light from lamps or bulbs 130 through one or moreopenings 136, which openings are preferably closed and covered by lenses135. Mirror assembly 10 also preferably includes a day/night toggleactuator assembly 22 connected to a pivotally adjustable support arm 24and amounting bracket 26 adapted to be received on windshield mountedbutton B on windshield W (FIG. 2), or on a header mount at the upperedge of the windshield in conventionally known fashion. Once carriermember 20 is mounted within mirror case 12 after insertion of actuatorassembly 22, reflective mirror element 14 is assembled within the mirrorcase and retained in position by front mounted retaining bezel 18 havingflanges or projections 19 spaced therearound for engaging the innersurface of the periphery of mirror case 12 (FIG. 1). Projections 19 arepreferably received and ultrasonically welded in mounting brackets 21spaced around the interior of the peripheral wall 30 of case 12. Bezel18 alternately may be adapted for snap-fitting into place viaprojections 19. Preferably, mirror case 12 is molded in one piece andincludes a back or rear wall 28 and a continuous peripheral, side wall30 defining a peripheral edge 32 and a front opening 34. A pair ofspaced, generally vertical internal walls 36 extend between the top andbottom portions of the peripheral side wall 30 within the hollowinterior of case 12 to define a space therebetween for receivingday/night toggle actuator assembly 22. An opening 38 between the topside wall portion and back 28 of case 12 allows insertion of mirrorsupport arm 24 and mounting bracket 26 therethrough when actuatorassembly 22 is mounted. Preferably, mirror case 12 and retaining bezel18 are injected molded from non-electrically conductive, resinous ABSplastic, such as that sold under the trademark TERLURAN KR2889, by BASFCompany of Wyandotte, Mich. Alternately, other resinous, meltprocessable plastics or moldable materials such as glass filled nylonand polypropylene could be used to form case 12. A suitable nylon is 13%glass modified nylon 6:6 sold as ZYTEL 71G13L by I.E. DuPont de Nemours& Company of Wilmington, Del., or PA123G13BK-47 by Bay Resins Inc. ofMillington, Md. A suitable polypropylene is TENITE P6M4Z-007 by EastmanChemical Products, Inc., Kingsport, Tenn.

Preferably, reflective mirror element 14 is formed from soda lime glassand has nonparallel front and rear surfaces, the rear surface preferablybeing coated with a highly reflective silver/chromium metal layer orother reflective surface. Alternately, clear plastic material such aspolycarbonate or acrylic may be used to form prismatic minor element 14.Scatterproofing/shatterproofing layer 16 is preferably formed from R101,a styrene butadiene rubber (SBR) polymer sold by Helmitin GmbH ofPirmasens, Germany, and is adhered to the rear surface to preventscattering of glass fragments and shards in the event of glass breakageduring an accident or the like. Alternately, an adhesive tape could alsobe used for layer 16.

Actuator assembly 22 is preferably of the type described incommonly-assigned U.S. Pat. No. 5,327,288 to Wellington et al. entitled“Reduced Vibration Day/Night Rearview Mirror Assembly,” the disclosureof which is hereby incorporated by reference herein. As shown in FIGS. 1and 2, actuator assembly 22 includes a toggle member 40 and a pivotlever 42, each preferably molded of a thermoplastic material such as 13%glass filled nylon. Toggle 40 includes a pivot journal 44 formed alongits top edge, which journal corresponds to pivot axle 39 adjacentopening 38 at the upper rear of mirror case 12. Generally trapezoidaltoggle 40 is preferably molded with a pattern of multiple voids definedby interconnecting, interior structural webs with a zinc die castmounting ball 46 molded into and projecting outwardly from the back oftoggle 40 in aperture 48 (FIG. 1). A generally rectangular aperture 50extends through the entirety of toggle 40 adjacent its upper edge forreceipt of an external power source connector plug 51, as described morefully hereinafter. A pivot tab or flange 52 extends downwardly fromactuator 40 and engages the upwardly facing channel 54 on pivot lever 42which is pivotally mounted between walls 36 within case 12 underactuator 40. Preferably, a spring bar is molded into the lower area oftoggle 40 as is disclosed in U.S. Pat. No. 5,327,288. Thus, by pivotinglever 42 forwardly or rearwardly, minor case 12 and thus reflectivemirror element 14, carrier member 20 and bezel 18 are pivoted about axle39 in journal 44 to change the position of mirror element 14 between ahighly reflective day position in which light rays are reflected fromthe reflective rear surface of element 14 to the viewer, and a reducedreflectivity night position in which light rays from behind the vehicleare reflected from the front surface of mirror element 14.

The support arm 24 and mounting bracket 26 can be of any known varietyincluding two ball pivot support arms, breakaway mounts adapted formounting on the windshield button B as disclosed in commonly-assignedU.S. Pat. No. 5,327,288 to Wellington et al., or header mounted supportarms as disclosed in commonly-assigned, U.S. Pat. No. 5,615,857, toRichard R. Hook entitled “Mirror Support Bracket,” the disclosures ofwhich are hereby incorporated by reference herein. Alternately, toggleactuators other than assembly 22 could be substituted in mirror assembly10 within the concept of the present invention.

As is best shown in FIGS. 1 and 3-10, the integrated subassembly moduleor carrier member 20 preferably is a molded, thermoplastic, resinoussupport body 60 having a generally rectangular shape with its lengthgreater than its height and a thickness preferably within the range of0.08 to 0.25 inches, and more preferably of 0.08 to 0.15 inches. Astamped, metallic wire or other separately formed circuit member 62(FIG. 4) is preferably insert molded within the carrier member supportbody 60 such that the circuit member is at least partially encasedand/or encapsulated therein with selected electrical contacts projectingfrom the support body.

As is best seen in FIG. 4, the preferred form of the preformed circuitmember 62 is stamped from metal such as brass or UNS-C26000 ¾ hard brasshaving a thickness of about 0.025 inches to include a series of busstrips 64 which extend and distribute electricity to bulb holders 66 andelectrical switches 68 from external electrical connections 70.Alternately, rigid or flexible metallic wire could also be used. Thus,bus member 64 a extends from electrical plug connection 70 a to switchcontacts 68 b, 68 c forming one side of the electrical connection foreach of two separate switches 72 a, 72 b. A separate bus strip 64 bextends from electrical connection 70 b to bulb holder 66 a and 66 dwhich form one side of each of two sets of clip-type, bulb holders orreceptacles 66. A third bus strip 64 c extends, between bulb holder 66 band connection 68 a for switch 72 a, while a fourth bus strip 64 dextends from bulb holder 66 c to electrical connection 68 d for anotherelectrical switch 72 b. Electricity from plug connections 70 a, 70 b isdirected through switches 72 a, 72 b selectively to bulb holder sets 66a, 66 b or 66 c, 66 d holding separate lamps or light bulbs 130. In apreferred form, circuit member 62 is formed with integral punch out orknock out plugs 74 a, b, c and d which are removed following insertmolding of the circuit member within support body 60 to formelectrically isolated bus strips as described below.

As is best seen in FIGS. 1, 3 and 5, support body 60 is preferablymolded to include spaced, square or rectangular apertures 80, 82 throughwhich extend bus strips 64 b, 64 c and 64 d generally at a right angleto the rear surface of support body 60. Bulb holders 66 a, 66 b and 66c, 66 d are thus spaced outwardly from the rear surface of the supportbody on those bus strips and open downwardly for receipt of suitablewedge-base light bulbs 130 which may optionally be gas filled for longerlife and preferably have a luminous intensity less than or equal to four(4) candlepower, and more preferably less than or equal to three (3)candlepower. Centered beneath each aperture 80, 82 is an elongated,vertically extending slot 84, 86, respectively, adapted to receive andmount reflectors 110, 112 therein as described below. Spaced inwardlyfrom each slot 84, 86 is a rectangular recess or pocket 88, 90,respectively, adapted to slidingly receive switches 72 b, 72 a,respectively, from the bottom opening thereof. Each recess 88, 90includes a forwardly projecting wall 89, 91 on the front side of supportbody 60, which walls each include a slot contoured to receive theprojecting plunger from switch 72 a, 72 b. A rectangular plug receptacle92 is molded at the top center of support body 60 for receipt of anexternal power source connector plug 51 (FIGS. 1 and 2) through opening50 of toggle member 40 in actuator assembly 22 as described above.

Preferably, carrier member 20 is an insert molded assembly with circuitmember 62 preformed and inserted within a suitable mold cavity andsupport body 60 molded therearound to partially encase and/orencapsulate the circuit member within the support body such that thevarious electrical connections, plugs and bulb holders project from thesupport body. The preferred material for the support body of carriermember 20 is a melt processable, thermoplastic material such as nylonpreferably a glass and/or mineral filled nylon such as 30% glass fillednylon, or PBT 33% glass filled nylon such as CELANEX 3300 available fromHoechst Celanese Company of Somerville, New. Jersey, while the preferredprocess is injection molding. Alternately, compression molding,extrusion molding, reaction injection urethane molding or casting of thesupport body about the circuit member 62 can be used. Thus, carriermember 20 is preferably integrally molded to include an electricalcurrent carrying conductor 62 capable of carrying electricity of greaterthan one (1) amp such that the electricity is conducted and distributedfrom a connection to an external electrical source to the variouselectrical components on member 20 such as lamps, switches, controls,instruments, or the like. It is also possible to premold the supportbody in two halves such that the halves include a cavity therebetweenand place the circuit member 62 between the two halves and secure themtogether such as by snap-fitting, ultrasonic welding or the like. Asanother alternative, the molded support body can be preformed to includechannels or receptacles for the circuit member 62 with the preformedcircuit member being secured to at least one surface of the support bodysuch as in snap-in fashion. In such case, just as in the above moldingmethod, at least a portion of the circuit member would be held byportions of the support body and project therefrom. The molding ofcarrier member 20 can also incorporate a receptacle for connection orplugging in of a PC circuit board for various alternative functionswithin the vehicle after mounting of the minor assembly, as is explainedbelow in connection with assembly 270.

After molding or other formation of carrier member 20, punch out orknock out areas 94, 96, 98 and 100 (FIGS. 1, 3 and 5) are pierced ormoved out of the support body and circuit member to delete the punchouts or knock outs 74 a, 74 b, 74 c and 74 d thereby completelyseparating and electrically insulating the bus strips 64 a, 64 b, 64 cand 64 d from one another. This prevents electrical shorting within thecircuit member. The resinous, thermoplastic material preferably used forthe support body 60 is also non-electrically conductive and forms aninsulating barrier between the bus strips to prevent electricalshorting.

Referring now to FIGS. 1, 5 and 7-14, reflectors 110, 112 are adaptedfor removable mounting on circuit member 20. Preferably, reflectors 110,112 are molded from a high temperature resistant (i.e., greater than100° C. preferred), thermoplastic, melt processable resinous plasticmaterial, preferably polycarbonate, although acrylic may also be used.Each reflector is substantially similar although including a slightlydifferent shape depending on the area of the vehicle intended to beilluminated. For reference purposes, reflector 112 is described as shownin FIGS. 11-14, although it should be understood that reflector 110includes substantially the same elements. Reflector 112 includes acurved, hollow, bulbous reflector body 114 having an integral mountingflange 116 projecting to one side thereof and a bulb receiving tube 118projecting upwardly and defining a bulb receiving aperture 120. Thelower periphery 122 of the molded reflector lies in a plane and definesa generally circular profile for reflector 112 although othershapes/profiles may also be used such as a generally elliptical profilefor reflector 110 as shown in FIG. 7. Reflector 110 is somewhat moreelongated utilizing that generally elliptical profile to direct lightboth downwardly and to one side of the mirror assembly when mounted in avehicle so as to properly illuminate the lap or seat area of thepassenger side of the front seat of a vehicle, while reflector 112directs light downwardly and toward the driver lap or seat area of thevehicle front seat as shown in FIG. 10. The inside surface 124 of thereflector body 114 is preferably vacuum metalized to provide a highlyspecular, shiny reflective surface efficiently directing light raysdownwardly and in the intended direction from bulb 130 when received inaperture 120.

As is best seen in FIGS. 5, 7 and 11-13, the vertically extending edge126 of mounting flange 116 is inwardly tapered to mate with acorrespondingly tapered slot 84 or 86 (FIG. 7) when edge 126 is slidablyinserted at the bottom of slot 84 or 86. The taper of the slot andmolded edge forms a dovetail joint which prevents removal of thereflector from the carrier member in a direction perpendicular to theplane of the carrier member while maintaining flange 116 generallyperpendicular to the plane of member 20. In addition, slots 84, 86 aregenerally aligned with bulb holders 66 at either end of carrier member20 such that when wedge-base light bulbs 130 are inserted in the bulbholders, and project downwardly therefrom as shown in FIGS. 1, 5, 8 and9, the sliding of the reflectors 110, 112 into slots 84, 86 causes lightbulbs 130 to be telescopingly inserted in apertures 120 of tubes 118such that the bulbs extend through these apertures and at leastpartially into the bulbous, hollow, reflector body 114 adjacentreflectorized surface 124. The bulb filament is, therefore, locatedwithin the hollow area defined by the reflectorized surface to properlydirect light rays downwardly and toward the driver's seat area. The sameis true of reflector 112 which directs light downwardly and toward thelap or seat area for the front seat passenger of the vehicle from theposition of the rearview mirror assembly when secured to the centerportion of the windshield above the instrument panel area.

As shown in FIGS. 1, 10 and 15-17, the final elements of mirror assembly10 include lens elements 135 which are substantially similar to oneanother on either end of the assembly. Each lens element 135 is aslightly curved molded plastic body having the general shape of anellipse, as is best seen in FIG. 15. Preferably, the lens elements areformed from an acrylic or polycarbonate material which is adapted to bescattering (such as by forming a stippled, scattering surface duringmolding of the lens element itself by providing a stippled surface inthe mold cavity) to provide a diffused, translucent appearance. Thus, inassembly 10, neither lens is used as a focusing element, but ratherprovides diffused light to illuminate a wide area in the driver orpassenger seat area. Alternately, lens 135 can be a diffuse optic, aclear optic, a holographic optic, a Fresnel optic, a binary optic, asinusoidal optic, a diffractive optic or a tinted optic element asdesired. Preferably, lens elements 135 are retained in elliptical lensopenings 136 at either end of mirror case 12 (FIG. 1) by tapered,retaining prongs 138, one prong at either end of each lens element.

As will also be understood, reflectors 110, 112 can also be manufacturedfor adjustment once mounted on the carrier member 20. Mounting flange116 could thus be pivotally or swivelly mounted to reflector body 114 soas to allow adjustment of the position of the reflector and thus thedirection of the light emanating from the bulb 130 inside each reflectorwhen adjusted. As shown in the embodiment of mirror assembly 10,however, reflectors 110, 112 are positioned in specific, fixed positionson the carrier member at specific angles to direct light in a specificdirection for a predetermined vehicle. Alternately, other lenses whichare clear and have light focusing or directing surfaces thereon could beused to further direct the light emanating from the reflector housingsthrough case openings 136 so that predetermined areas of the vehicle canbe illuminated.

As will now be understood, assembly of the modular rearview mirrorassembly 10 will be apparent. A preassembled toggle actuator assembly 12is inserted within the previously molded mirror case 12 by insertingbracket 26 through opening 38 from the interior of the case toward therear of the case. Toggle actuator 40 is then slid into position suchthat pivot axle 39 engages journal 44. Pivot tab 52 is engaged withchannel 54 of pivot lever 42 during insertion of toggle actuator 40 suchthat it is properly retained in position. Next, carrier member 20 ispreassembled with the light bulbs 130, reflectors 110, 112, electricalswitches 72 or other electrical components thereon. More specifically,electrical switches 72 a, 72 b are slid into recesses 88, 90 such thatelectrical connections 68 a, 68 b and 68 c, 68 d are plugged intocorresponding receptacles in the switches as shown in FIG. 4. Next,wedge-base light bulbs 130 are inserted in bulb holders 66 a, 66 b and66 c, 66 d. Thereafter, reflectors 110, 112 are each slid over bulbs 130by engaging tapered flange 126 with slot 84 or 86 and moving thereflector upwardly into position over the bulb as shown in FIG. 8.

Following preparation of the modular integrated subassembly of carriermember 20, that subassembly is inserted by placing the carrier assemblyinto the interior of mirror case 12 with plug receptacle 92 extendinginto and/or aligned with aperture 50 of toggle actuator 40. The carriermember is received with the bottom periphery 122 of each reflectorhousing immediately adjacent the periphery of opening 136 such thatperiphery 122 is abutted against the inside surface of the peripheralside wall of the mirror case adjacent the opening 136. This isaccomplished by dropping the lower edge of the carrier member 20 intothe space between retaining rib 140 spaced outwardly of the front edgesurfaces of walls 36 on the interior bottom portion of case wall 30(FIGS. 1 and 2), followed by rotating the top edge in toward theactuator 40 until it is properly positioned with the reflectors andlight bulbs in alignment with openings 136, and abutted against theexposed edge surfaces of walls 36. In this position, ribs 142 a, 142 bon the rear surface of carrier member 20 engage the outside surfaces ofwalls 36 to restrain lateral movement of carrier member 20 within thecase.

Subsequently, reflective mirror element 14 is similarly placed in theinterior of case 12 within the perimeter of peripheral side wall 30followed by inserting and securing retaining bezel 18 either by snap-fitclips 19 or ultrasonic welding. As shown in FIG. 2, the rear ofpolymeric layer 16 resiliently engages the upper front surface ofcarrier member 20 to hold the carrier member and prevent vibrationthereof. Once rearview mirror assembly 10 is mounted in the vehicle asshown in FIG. 2, a plug connector 51 from the vehicle power source canbe inserted through opening 50 in actuator 40 and engaged with theelectrical connectors 70 a, 70 b in plug connection 92 at the rear ofthe carrier member to provide external power to the carrier member andelectrical components such as light bulbs 130 thereon. When assembled inthis fashion, the plungers of switches 72 a, 72 b extend through thelower portion of bezel 118 and specifically apertures 21 a, 21 b throughwhich push buttons 73 a, 73 b extend for operation of the switches andthus the light bulbs electrically connected thereto.

When installed in this manner in a rearview, mirror case or housing,carrier member 20 provides a support, positioning element and electricaldistribution network for electrical components such as light bulbs 130and electrical switches 32. However, the carrier member also provides astrengthening member serving as a reinforcement or buffer between toggleassembly 22 and reflective mirror element 14 to retain the toggleassembly in place in the event of impact due to inflation ofsupplemental occupant restraint systems, also known as airbags, withinvehicles as is explained in commonly-assigned U.S. patent applicationSer. No. 08/273,491, filed Jul. 11, 1994, by Harold W. DeYoung et al.,now U.S. Pat. No. 5,521,760, the disclosure of which is herebyincorporated by reference herein.

With reference to FIGS. 18-21, a second embodiment 150 of the modularrearview mirror assembly for vehicles of the present invention is shown.Mirror assembly 150 incorporates a modified mirror case or housing 12′which is substantially similar to mirror case 12 except for beingpreferably molded from polypropylene, or alternately frompolypropylene/polyethylene copolymer, and having the peripheral edge 32′of peripheral side wall 30′ formed with lip 32′. Instead of using atwo-piece mirror case including a retaining bezel as in embodiment 10,mirror case 12′ incorporates a molded lip on peripheral edge 32′ (FIG.19) which allows snap-in insertion of reflective mirror element 14′immediately following molding of case 12′ and when peripheral side wall30′ is still warm and relatively flexible. Specifically, prismaticmirror element 14′ has a periphery which is slightly larger than thefront opening to the mirror case defined by lip 32′ as shown in FIG. 19.While mirror case 12′ is still warm and relatively flexible, mirrorelement 14′ can be snapped past the lip 32′ into the position shown inFIG. 19 such that when mirror case 12′ completes its cooling, the mirrorcase shrinks around the periphery of mirror element 14′ to secure it inposition and prevent rattling and vibration during use. In addition,mirror case 12′ includes switch access openings 152 a, 152 b on eitherside of the toggle actuator assembly adapted to register with switcheson the carrier member 20′ when assembled within case 12′.

The preferred polypropylene material of one-piece case 12′ has a lowerheat deflection temperature, lower material cost, and higher materialshrinkage rate than the preferred ABS or glass-modified nylon materialsused for two-piece housing 12 described above. In spite of its lowerheat deflection temperature, degradation of the one-piece polypropylenecase from heat generated by the lamps in the assembly is obviated due tothe efficiency of the highly reflective reflectors 110′, 112′ andoverall efficient heat management within the assembly. As an aid to heatdissipation from the assembly, air ventilation passageways extendingthrough case 12′ and past and around the lamps and reflectors in theassembly can optionally be used as disclosed in commonly-assigned U.S.Pat. No. 5,178,448, the disclosure of which is hereby incorporated byreference herein.

For example, the heat deflection temperatures, determined under ASTMStandard D 648-88, of the preferred materials for cases 12 and 12′ are:

@ 264 psi @ 66 psi ZYTEL 71G13L Glass-Modified Nylon 446° F. 491° F.TERLURAN KR2889 ABS 223° F. 234° F. TENITE P6M4Z-007 Polypropylene 125°F. 181° F.

Likewise, the mold shrinkage rate for the preferred materials for cases12 and 12′ are:

ZYTEL 71G13L Glass-Modified Nylon .008-.014 inch/inch ABS Polymer.003-.004 inch/inch TENITE P6M4Z-007 Polypropylene .010-.025 inch/inch

Thus, it is preferred that the material shrinkage rate for the materialof one-piece case 12′ be greater than 0.010 inch/inch.

In addition to the above modified mirror case 12′, mirror assembly 150includes a modified circuit member 62′ (FIG. 21) which is preferablyinsert molded in a support body 60′ to form carrier member 20′ in thesame manner as described above for assembly 10. Like circuit member 62,circuit member 62′ is preferably stamped from sheet metal such as brassor formed from metallic wire to include a plurality of bus stripsproviding electrical connections within the carrier member. Each of thebus strips is substantially similar to those in circuit member 62 exceptthat the lower ends of bus strips 64 a′, 64 c′ and 64 d′ are modifiedsuch that tapered prongs or electrical connectors 68 a′, 68 b′, and 68c′, 68 d′, extend at right angles to the remainder of the bus strip andin the same direction in which the bulb holders 66 and electricalconnections 70 extend. As shown in FIG. 20, when circuit member 62′ isinsert molded or otherwise encapsulated at least partially withinsupport body 60′ of carrier member 20′, prongs 68 a′, 68 b′ and 68 c′,68 d′ extend into recesses 88′, 90′ such that electrical switches 72′can be inserted into those recesses and plugged into the electricalconnections in a direction substantially perpendicular to the plane ofcarrier member 20′. This is different from the insertion of switches 72a, 72 b which are inserted in a direction substantially parallel to theplane of carrier member 20 from the bottom of recesses 88, 90 as shownin FIGS. 3 and 4.

Accordingly, with reference to FIGS. 18 and 19, once carrier member 20′forming an integrated subassembly module is assembled with appropriatereflectors, light bulbs and switches in the aforementioned manner, suchthat the plungers of switches of 72′ extend downwardly with switchbuttons 73′ mounted thereon, carrier member 20′ may be inserted withinmirror case 12′ by placing the lower edge within the case between rib140′ and the front surfaces of walls 36′ and rotating the top edgetoward the toggle actuator assembly such that switch plungers passthrough switch openings 152 a, 152 b. Carrier member 20′ then abutsagainst the front edges of walls 36′. All of this occurs within arelatively few seconds after the case 12′ has been removed from the moldwhere it is formed. During this time period, the preferred polypropyleneor polypropylene/polyethylene copolymer material of case 12′ is stillwarm and is preferably at a temperature of approximately 120° F. to 210°F., and more preferably 135° F. to 165° F. It takes but a few seconds toinsert carrier member 20′ in the above manner after which the prismaticreflective mirror element 14′ may be mounted by snapping it pastretaining lip 32′ which is still in its warm and relatively flexiblestate as described above. The rear of polymeric layer 16′ engages thetop, front surface of carrier member 20′ to hold it against the frontedges of walls 36′ and prevent rattling and/or vibration of the carriermember within case 12′. Thereafter, assembly 150 is allowed to cool suchthat the case 12′ further shrinks tightly about the peripheral edge ofcarrier member 20′ and reflective mirror element 14′ to help hold themsecurely in place against vibration and rattling. Subsequently, lenselements 135′ may be inserted in lens openings 136′ to complete theassembly. An electrical connector is inserted to engage connections 70a′, 70 b′ through aperture 50′ of actuator 40′ once the mirror ismounted in the manner described above.

With reference to FIGS. 22-29, a third embodiment 170 of the modularrearview mirror assembly of the present invention is illustrated. Mirrorassembly 170 includes a hollow molded mirror case 172 preferably formedfrom polypropylene and including a formed lip 174 similar to that usedin connection with mirror assembly 150 allowing snap-in insertion of areflective prismatic mirror element 175 having a shatterproofing layerthereon (FIG. 23). Also included is a toggle actuator assembly 176connected to a support arm and mirror bracket similar to that used inembodiments 10 and 150 except that toggle actuator assembly 176 isformed in one piece with pivot lever 178 joined by a living hinge 180 toa spring bar 182. In addition, toggle actuator 184 is pivotally mountedon axles 186 near the top of the rearview mirror assembly betweenvertical walls 177. In addition, there is no through aperture in theactuator assembly for receipt of an external power connection since thecarrier member 190 used in assembly 170 includes its own receptacle forsuch a power connection.

Instead of a rectangular carrier member on which are mounted spacedlamps and reflectors for illumination from either end of the mirrorassembly as in embodiments 10 and 150, and which is assembled prior toinsertion of the reflective mirror element to close the mirror case,mirror assembly 170 includes a removable carrier member 190 which atleast partially encapsulates a circuit member 192 (FIG. 28), a lamp orbulb 130, a stamped metallic reflector 194, a switch assembly 196, alens element 198 and a plug receptacle 200 for receiving an externalpower connector, Carrier member 190 with these elements can be insertedand removed from mirror case 172 after mounting and assembly of mirrorelement 175 behind snap-in lip 174 to provide for servicing and repairof the lamp or light unit in the carrier member or for access to theinterior of the mirror case for any other reason. As shown in FIG. 22,when mounted in the mirror assembly, the toggle operator 197 of switch196 protrudes slightly below the peripheral side wall at the bottom ofthe mirror case for access and operation.

As is best seen in FIGS. 23-27, carrier member 190 includes a generallyrigid body or support 201 preferably formed from polypropylene andhaving a generally trapezoidal shape when viewed from the top or bottomconforming to the shape of an opening 202 in the bottom wall of mirrorcase 172 (FIG. 23). Rigid body 201 includes an upstanding wall 204 onits top surface in which is molded and at least partially encapsulatedcircuit member 192 (FIG. 28) such that various electrical connectionsextend therefrom. Formed integrally with wall 204 is a hollow, bulbousreflector mount or receptacle 206 from which a bulb mounting socket 208extends upwardly and includes a through aperture 210 into which extendbulb holders or connectors 252 a, 252 b from circuit member 192. At theopposite end of rigid body 201 is a switch receptacle 212 moldedintegrally with wall 204 and including a through aperture 214 into whichextend electrical connectors 256 a, 256 b from circuit member 192. Onthe rear side of wall 204 is molded integrally a plug connector 200forming a rectangular receptacle for receiving an external powerconnector into which extend electrical connections 254 a, 254 b fromcircuit member 192. Integrally molded with plug connection 200 areresilient prongs or barbed fingers 216 adapted to engage the insidesurface of an internal wall or rib 218 which outlines an aperture 220through the rear wall 179 of min or case 172. In addition, rigid body201 also includes an upstanding peripheral wall 222 (FIGS. 24 and 25)extending around the edge of the body, an upstanding, substantiallyrigid L-shaped flange 224 at one end, and a pair of resilient prongs orretaining fingers 226 at the opposite end. The bottom surface 228 ofrigid body 201 defines a pair of spaced openings 230, 232, and a recessarea 234 surrounding opening 230. Recess 234 is matched to theconfiguration and outline of lens element 198 and includes two spacedpair of openings 236, 238 adapted to receive barbed securing fingers orprongs 240 on the upper surface of lens element 198. Lens element 198may thus be removably inserted in recess 234 such that it is flush withsurface 228 to cover opening 230 and close the chamber inside reflector194 as will be more fully described below. Likewise, opening 232receives switch assembly 196 therethrough from the bottom such that rim242 on switch 196 engages bottom surface 228 of rigid body 201 adjacentopening 232 (FIG. 23). Toggle 244 for switch 196 is thus accessible fromthe bottom surface of the mirror and carrier member 190. Lens element198 is preferably formed from an acrylic or polycarbonate, moldedmaterial and may be either clear or cloudy/translucent to providefocused light in which case various lens surfaces will be provided onthe lens element or diffuse light for illumination of a general areawithin the vehicle.

As shown in FIG. 28, circuit member 192 is preferably stamped from thinbrass or other suitable metal and includes three bus strips 250 a, 250b, and 250 c. Bus strip 250 a extends from clip-type bulb holder 252 ato plug connector 254 a at its opposite end. Bus strip 250 b extendsfrom clip-type bulb holder 252 b to switch engaging electricalconnection 256 a at its opposite end. Bus strip 250 c extends fromswitch engaging electrical connection 256 b at one end to plugconnection 254 b at its opposite end. Preferably, the brass circuitstamping is formed with punch out or knock out portions 258 a and 258 bbetween bus strips 250 a and 250 b and a separate brass stamping busstrip 250 c. These members are placed in a suitable mold cavity andcarrier member 190 is preferably injection molded therearound to form anintegral molding which at least partially encapsulates the circuitmember 192 therein such that bulb holders 252, and electricalconnections 254, 256 extend therefrom in the indicated apertures forconnection to the various electrical components. Of course, as explainedabove in connection with carrier member 20, other molding methods may beused such as compression molding, extrusion molding, reaction injectionmolding for urethane or casting. As is best seen in FIG. 24, reflector194 is preferably stamped from aluminum, has the shape of a compound ordouble parabola, and is highly polished on its inside surface 260 forhigh and specular reflection of light from light bulb 130. Alternately,the reflector shape can be molded in wall 204 and have its insidesurface vacuum metalized just as with reflectors 110, 112 to providehigh, specular reflection. Reflector 194 also includes an upper opening262 through which the light bulb 130 extends when mounted in bulbholders 252 a, 252 b, as shown in FIG. 23. The shape of the hollow bodyportion of reflector 194 is parabolic on each side of lamp 130. As shownin FIG. 23, the specific shape is that of a double or compound paraboladesigned to collect light and direct it both to the driver and frontseat passenger lap areas. Reflector 194 is adapted to correspond to theinternal surface of the reflector receptacle 206 molded integrally withcarrier member 190 as described above.

Accordingly, assembly of mirror assembly 170 will now be apparent.Carrier member or integrated subassembly module 190 is first assembledby placing reflector 194 within receptacle 206 from the bottom surface228 of body 201 of the carrier member. Thereafter, a wedge base light130 is inserted through the bottom opening of the reflector 194 into thebulb holders 252 a, 252 b such that the bulb extends through reflectoropening 262, as shown in FIG. 23. Thereafter, lens element 198 isinserted by engaging prongs or fingers 240 in apertures 236, 238.Finally, switch assembly 196 is inserted through opening 232 such thatits electrical contacts engage contacts 256 a, 256 b of circuit member192.

With the carrier member subassembly completed in the above manner, thatassembly is inserted through bottom opening 202 in the mirror 172 suchthat wall 204 extends upwardly and plug receptacle 200 is aligned withopening 220 in the rear wall of mirror case 172. Prongs or fingers 216are then engaged with the inside surface of rib or wall 218 on the rearinside of case 172 to engage the plug receptacle within opening 220 andprevent it from being pushed into the interior of the case when anexternal plug connector is engaged. Simultaneously, flange 224 isengaged over a wall adjacent opening 220 while resilient prongs 226 flexand engage the inner surface of the bottom wall of the mirror case 172at the opposite end of the carrier member to complete assembly. Shouldremoval be desired, a tool such as a screw driver can be insertedthrough slot 264 adjacent resilient fingers 226 to flex the fingers andallow pivotal removal of carrier member 190 from opening 202 afterdisengagement of the plug receptacle 200 and ribs 216 from the rib 218toward the top of the case.

Referring now to FIGS. 30 and 31, a fourth embodiment 270 of a modularinterior rearview mirror assembly incorporating the present invention isshown. Assembly 270 is of the type described in published EuropeanPatent Application No. 0 615 882 A2, filed Mar. 18, 1994, the disclosureof which is hereby incorporated by reference herein. The assemblyincludes a mirror case 272 which, like mirror cases 12, 12′ and 172above, is preferably molded from a resinous, thermoplastic or thermosetplastic which may be reinforced with fibers, adapted for mounting on avehicle windshield by means of an adjustable mirror support. Instead ofa ball member extending outwardly from its rear side, mirror case 272includes a socket 274 for receiving a ball member extending outwardlyfrom the mirror support, and has a rear wall 276, and a peripheral wall278 having top, bottom and end portions. Socket 274 is formed in arecess 280 in the rear wall of the case, as shown in FIG. 30. The mirrorcase also includes a plurality of support flanges integrally formed onthe interior surface of the mirror case 272 to support a variablereflectance, electro-optic mirror cell 282 more fully described below. Aforward facing light sensor (not shown) extends through rear wall 280while a second light sensor (not shown) faces rearwardly. Electro-optic,reflective mirror cell 282, which preferably is an electrochromic celleither of the solid-state type or the electrochemichromic type, ismounted in the rearwardly facing opening of mirror case 272 and heldtherein by a peripheral bezel 284 as shown in FIGS. 30 and 31. A layerof foam material 286 is adhered to the rear surface of mirror cell 282and covers substantially the entire rear surface of the cell exceptwhere items such as through-the-cell photodetectors and informationdisplays, such as compass displays, are mounted behind the mirror. Foamlayer 286, such as a cross-linked polyethylene foam, acts as a resilientshock absorber to reduce the risk of breaking the mirror element duringan impact, and includes an adhesive layer applied to both its front andrear surfaces. One adhesive surface of the foam is adhered to the rearsurface of mirror cell 282. The second adhesive surface provides anattachment for a printed circuit board 288 mounted thereon. The rearsurface of circuit board 288 which faces away from mirror cell 282carries various electrical components of an electrical circuit used tocontrol operation of the electro-optic mirror cell such as a circuit,for example, like that described in commonly-assigned U.S. Pat. No.4,886,960, the disclosure of which is hereby incorporated by referenceherein. Printed circuit board 288 also includes a two-positionelectrical switch (not shown) for on/off control of the electro-opticcircuit.

Preferably, variable reflectance, electro-optic reflective mirror cell282 is an electrochromic mirror cell that includes a transparent, frontglass sheet 290 and a transparent, rear glass sheet 292 having areflective coating 294 applied to its rear surface. Front glass 290 andreflective rear glass 292 are slightly offset relative to one anothersuch that the upper and lower edges project for connection toappropriate metal connection strips (not shown). A variable lighttransmittance, electrochromic medium 296 is sandwiched in the spacebetween the front glass 290 and rear glass 292. The front surface ofrear glass 292 and rear surface of front glass 290 each have atransparent electroconductive coating, such as indium tin oxide or dopedtin oxide or the like, to conduct electricity across the full contactextent of electrochromic medium 296 from the connection strips securedat the offset top and bottom of the front and rear glass sheets. Whencontrolled by printed circuit 288, electrical voltage is applied acrosselectro-optic cell 282 between front glass 290 and rear glass 292causing a variation in the transmittance of layer 296 such as darkeningor opacity to reduce the light reflected by the reflective rear glass292. Electrochromic medium 296 may, for example, be anelectrochemichromic medium such as is described in commonly-assignedU.S. Pat. Nos. 5,140,455 and 5,151,816 or a solid-state electrochromicmedium such as described in the following publications: N. R. Lynam,“Electrochromic Automotive Day/Night Mirrors”, SAE Technical PaperSeries, 870636 (1987); N. R. Lynam, “Smart Windows for Automobiles”, SAETechnical Paper Series, 900419 (1990); N. R. Lynam and A. Agrawal,“Automotive Applications of Chromogenic Materials”, Large AreaChromogenics: Materials and Devices for Transmittance Control, C. M.Lampert and C. G. Granquist, EDS., Optical Engineering Press, Washington(1990), the disclosures of which are each hereby incorporated byreference herein.

Supported to the rear of circuit board 288 is an integrated subassemblymodule or carrier member 20″ similar to that used in assembly 10 above.Carrier member 20″ is also a molded, thermoplastic, resinous supportbody incorporating an integrally molded, preformed circuit member, pairsof bulb holders 66″, a pair of lamps or light bulbs 130 and a pair ofreflectors 110″, 112″, all of which are substantially similar to thoseon carrier member 20, formed and/or secured thereto as in carriermembers 20, 20′. Reflectors 110″ are positioned to direct light throughopening 281 in the case bottom and lens 135″. Carrier member 20″ alsopreferably includes a pair of electrical switches 72″ projecting throughbezel 284 for access and operation from the front in a manner similar toswitches 72 on carrier member 20 in assembly 10. Carrier member 20″further includes a plug receptacle 92″ on its rear surface and alignedwith an opening in case wall 280 for receiving a plug extending from thevehicle electrical system. Suitable electrical connections from carriermember 20″ to circuit board 288 are also included.

Assembly of mirror assembly 270 is similar to that for assembly 10above. After molding of case 272, previously prepared subassemblycarrier member 20″ is placed within the case interior. Nextelectro-optic mirror cell 282 with foam layer 286 and circuit board 288are placed as a unit within case 272 while making suitable electricalconnection between circuit board 288 and carrier member 20″. Bezel 284is secured by snap-fit clips or ultrasonic welding to retain thecomponents within the case as in assembly 10 with the electricalswitches from carrier member 20″ extending through bezel 284 for accessand operation of lamps 130 as in assembly 10. Lenses 135″ are thenfitted over openings 281. Thus, the carrier member subassembly of thepresent invention is useful with either manual day/night rearviewmirrors, or rearview mirrors incorporating electrochromic or otherelectro-optic reflective elements.

As shown in FIGS. 32-46, a fifth embodiment 300 of the modular rearviewmirror assembly of the present invention includes a molded, resinous,polymeric plastic mirror housing/case 302, a prismatic reflective mirrorelement 304, a resinous, polymeric, shatterproofing layer 306 applied tothe rear surface of reflective element 304, a molded, resinous,polymeric plastic day/night toggle actuator 308 for moving the caseassembly between day and night reflective positions, and a modularcarrier member or integrated subassembly module 310. Day/night toggleactuator 308 and carrier member 310 are adapted to be fitted within thehollow interior of molded housing/case 302 prior to snap-in insertion ofmirror element 304 therein. Carrier member 310 provides an integralsupport, electrical connections, and an electrical distribution networkfor one or more electrical components used within mirror assembly 302such as lamp or light bulbs 130, electrical switches 408 for controllingthe lamps or light bulbs, electrical contacts providing a plugconnection for a plug connector 312 for connecting the carrier member toan external power source such as the electrical system of the vehicle inwhich mirror assembly 300 is adapted to be mounted, or a diode 452adapted to be fitted to the circuit member 402 within carrier member 310to reduce or prevent electrical current leakage and thus battery drainfrom the vehicle electrical system when connected via plug connector312. As with the other mirror assembly embodiments mentioned above,carrier member 310 receives and mounts reflector housings or reflectors314, 316 which are adapted to direct light from lamps or bulbs 130through one or more openings 318 in the bottom wall of case 302, whichopenings are preferably closed and covered by lenses 380. Day/nighttoggle actuator 308 is preferably connected to a pivotally adjustablesupport arm and a mounting bracket of the type shown in FIG. 1 which areadapted to be received on a windshield mounted button B on windshield Wof the type shown in FIG. 2, or on a header mount at the upper edge ofthe windshield in conventionally known fashion.

With reference to FIGS. 32, 33 and 36, mirror case 302 is preferablymolded in one piece from polypropylene of the type sold under thetrademark TENITE P6M4Z-007 from Eastman Chemical Products, Inc. ofKingsport, Tenn., and includes a back or rear wall 320, and acontinuous, peripheral, side wall 322 which terminates in a peripherallip 324 defining a front opening 326. Like embodiment 150 of the mirrorassembly mentioned above, the molded lip 324 on mirror case 302 allowssnap-in insertion of reflective mirror element 304 immediately followingmolding of case 302 when peripheral side wall 322 is still warm andrelatively flexible. Prismatic reflective mirror element 304 has aperiphery which is slightly larger than the front opening 326 defined bylip 324. While mirror case 302 is still warm and relatively flexible,mirror element 304 can be snapped past lip 324 into the position shownin FIGS. 43-46 such that when mirror case 302 completes its cooling, themirror case shrinks around the periphery of the mirror element to secureit in position and prevent rattling and vibration during use.

As is best seen in FIGS. 32 and 43-46, mirror case 302 includes a seriesof internal ribs or walls within its hollow interior which extendbetween the top and bottom portions of the peripheral side wall 322 ingenerally vertical planes. Intermediate lens openings 318 are a seriesof four spaced walls 328 a, 328 b, 328 c, and 328 d which extend from aposition adjacent the snap-in lip 324 rearwardly along the bottom sidewall within the case to rear wall 320 vertically between the top andbottom side wall portions, and forwardly toward lip 324 along the topside wall. Each internal wall 328 a, 328 b, 328 c, and 328 d includes apair of generally vertically aligned slots 330 having a widthcorresponding to the thickness of carrier member 310. Slots 330 areadapted to receive corresponding recesses formed in the top and bottomedges of carrier member 310 as will be more fully explained below. Inaddition, the upper portion of walls 328 a, 328 b, 328 c, and 328 d eachinclude an inclined surface 332 (FIG. 46) adjacent the upper slot 330which cooperates with an inclined caroming surface in the correspondingrecess on carrier member 310 to allow snap-in insertion of the carriermember during assembly. The rearmost edges 331 of slots 330 engage therear surface of carrier member 310 for secure, non-vibratory supportwhen the carrier member is properly mounted in the slots as shown inFIG. 46.

As shown on FIGS. 32, 33, 36, and 43, a toggle access aperture 334 isformed in case 302 and extends from the bottom portion of side wall 322slightly into the rear wall 320. Toggle aperture 334 is generallycentered between lens openings 318 along the center line of housing of302. Spaced on either side of toggle aperture 334 and between walls 328b and 328 c are a series of horizontally spaced, vertical wall segments336 a, 336 b, 336 c, and 336 d (FIGS. 32 and 45) which include aligned,circular, bottom and top recesses or journals 338, 339 receiving theupper and lower cylindrical axles 340, 342 of toggle actuator 308 asshown in FIG. 45. Toggle actuator 308, in addition to axles 340, 342,includes a generally rigid body 344 from which a ball member 346 extendsrearwardly through rear opening 348 in rear wall 320. Axle 342 is joinedto body 344 by a compressible, U-shaped spring member 350 and aresilient web 352 (FIGS. 43, 44). Actuator mounting walls 336 b and 336c which are immediately adjacent either side of toggle aperture 334 eachinclude a generally vertically extending edge 354 which engages the rearmost edge of spring member 350 when pivot lever 356 and axle 342 arerotated to their night position shown in solid in FIGS. 32 and 43.Likewise, the rear surface of carrier member 310 includes an inclinedsurface 440 which is engaged by the forward most edge of spring member350 when pivot lever 356 is rotated on axle 342 to its day position asshown in phantom in FIG. 43. Area 440 thus forms a stop which engagesthe toggle actuator to limit its movement in the day position so as toposition the prismatic reflective mirror element 304 for proper viewing.Two pair of reinforcing ribs or walls 360, 362 extend generallyvertically on the inside surface of rear wall 320 and then forwardlyalong top side wall toward lip 324 generally above lens openings 318 foradded strength in the mirror case. In addition, ribs 364 are provided ateither end of case 302 on its inside end surfaces to provide stops forproperly positioning the ends of mirror element 304 when snapped intothe housing. Mirror case 302 also includes switch access openings 368 a,368 b on either side of the toggle actuator assembly and intermediatewalls 328 a, 328 b and 328 c, 328 d which openings are adapted toregister with switches on the carrier member 310 when assembled withincase 302.

As mentioned above in connection with embodiment 10, opening 348 in therear wall of the mirror case allows insertion of a mirror support andmounting bracket, such as support arm 24 and bracket 26 of embodiment10, therethrough when actuator 308 is mounted within the case bysnapping the pivot axles 340, 342 into circular recesses 338, 339. Thesupport arm and mounting bracket can be of any known variety asdescribed above in connection with embodiment 10. Alternately, toactuators other than that shown at 308 could also be substituted inmirror assembly 300 within the concept of the present invention.

By pivoting lever 356 of toggle actuator 308 forwardly or rearwardly,mirror case 302 and thus its reflective mirror element 304, carriermember 310 and lenses 380 are pivoted about axle 340 in journals 339 tochange the position of the mirror element 304 between a highlyreflective day position in which light rays are reflected from thereflective rear surface of the element 304 to the viewer and a reducedreflectivity night position in which light rays from behind the vehicleare reflected from the uncoated front surface of mirror element 304. Asabove, reflective mirror element 304 can be formed from soda lime-glassand preferably has nonparallel front and rear surfaces, the rear surfacebeing preferably coated with a highly reflective silver/chromium metallayer or other reflective surface. Alternately, a clear plastic materialsuch as polycarbonate or acrylic may be used to form prismatic mirrorelement 304. Scatterproofing/shatterproofing layer 306 is preferablyformed from R101, a styrene butadiene rubber (SBR) polymer mentionedabove concerning layer 16, and is adhered to the rear surface of mirrorelement 304 to prevent scattering of glass fragments and shards in theevent of glass breakage during an accident or the like. Alternately, anadhesive tape could also be used for layer 306.

Formed in the area between back wall 320 and the top portion ofperipheral side wall 322 at the rear of case 302 is a plug receptacle370 including a plug opening 372 adapted to receive plug connection 312when the mirror assembly is connected to a vehicle electrical system isexplained more fully below. Opening 372 includes a notch or recess 374therein, for receiving a latch member on the plug connection 312 asexplained below.

As shown in FIGS. 34-36, lenses 380 are preferably formed incorresponding, but mirror image, left and right hand versions, only oneof which will be described in detail herein. Each lens 380 is contouredto fit the complex curvature of the side and rear wall portions wherelens openings 318 are formed in case 302 and includes rectilinear edges382, 384 extending at right angles to one another and a curved edge 386.Each lens has a slightly convex outer surface 387 with its interiorsurface 388 being slightly concave and having stippling thereon forminga lightly frosted surface for defusion of light from bulbs 130 when thelamps are operated. Preferably, lenses 380 are formed from Dow 303Caliber Polycarbonate. Lenses 380 are held in openings 318 by retainingflanges 390 which extend along but are spaced inwardly from edges 382,384, and 386 on the inner surface 388 of each lens. Retaining flanges390 each include an outwardly extending, formed retaining lip 392defining a retaining shoulder 394 thereunder adapted to engage theadjacent edge of lens opening 318. Each of the retaining flanges 390 issomewhat resilient such that the curved outer surface of lip 392 allowseach flange to engage the edge of opening 318 upon insertion, and becammed slightly inwardly such that shoulder 394 will snap over theadjacent edge. As shown in FIG. 36, a notch 319 is formed in the curvededge of each opening 318 in order to allow insertion of a screwdriverblade or similar tool to pry lenses 380 outwardly for removal.

As best seen in FIGS. 37-42, the integrated sub-assembly module orcarrier member 310 preferably is a molded, thermoplastic, resinous,polymeric support body 400 having a generally rectangular shape with itslength greater than its height and a thickness preferably within therange of 0.08 to 0.25 inches and, more preferably, of 0.08 to 0.15inches. A stamped, metallic, wire or bus bar circuit member 402 isseparately formed and preferably insert molded within carrier membersupport body 400 such that the circuit member is at least partiallyincased and/or encapsulated therein with selected electrical contactsprojecting from this support body.

As is best seen in FIGS. 37 and 38, circuit member 402 is preferablystamped from metal such as brass or UNS-C26000 ¾ hard brass having athickness of about 0.025 inches to include a series of bus strips 404which extend and distribute electricity to two sets or pairs of bulbholders 406 and electrical switches 408 from electrical connections 410.Alternately, rigid or flexible metallic wire could also be used. Busmember 404 a extends from electrical plug connection 410 a to switchcontacts 412 a, 412 b forming one side of the electrical connection foreach of two separate switches 408 a, 408 b. A separate bus strip 404 bextends from electrical connection 410 b to switch contacts 414 a and414 b. A third bus member 404 c extends from electrical connection 410 cto bulb holders 406 a and 406 b which form one side of each of the twosets of clip type bulb holders or receptacles 406. A fourth bus trip 404d extends from switch contact 416 a to bulb holder 406 c, while a fifthbus member 404 e extends from switch contact 416 b to bulb holder 406 d.Preferably, switches 408 a, 408 b are single pole, double throw switcheswith an additional off position. Electricity from plug connections orcontacts 410 a, 410 b, 410 c is directed through switches 408 a, 408 bselectively to bulb holder sets 406 a, 406 c and 406 b, 406 d holdingseparate lamps or light bulbs 130. Preferably, circuit member 402 isformed with integral punch-out or knock-out plugs 418 a, 418 b, 418 c,418 d, 418 e, 418 f, 418 g, 418 h, and 418 i which are removed followinginsert molding of the circuit member within support body 400 by punchesextended through the support body to form openings or apertures 420 a,420 b, 420 c, 420 d, 420 e, 420 f, 420 g, 420 h and 420 i whichcorrespond to the location of the punch-out or knock-out plugs and,therefore, form the electrically isolated bus strips or members 404 a,404 b, 404 c, 404 d, and 404 e. Bulb holders 406 and electrical contacts410, 412, 414 and 416 are preferably formed by bending in progressivedies.

Preferably, as shown in FIGS. 32 and 37, switches 408; 408 b aretelescoped over electrical connections 412 a, 414 a, 416 a and 412 b,414 b, and 416 b such that plungers 409 a, 409 b extend downwardlythrough switch apertures 368 a, 368 b, respectively, when carrier member310 is mounted in case 302. Plungers 409 are adapted to be depressed tooperate the switches and thus the lamps/bulbs 130 connected to thecircuit member 402. Each plunger preferably includes a projection 411 a,411 b (FIG. 37) adapted to receive a symbol or other indicia indicatingthe operation of the switch. In addition, each switch plunger receives aflanged cap 415 a, 415 b, respectively, telescoped thereover such thateach projection 411 is visible through its aperture 417 a or 417 b incap 415 a or 415 b to allow visibility of the symbol on projections 411by a viewer using the mirror assembly in a vehicle. Preferably, eachswitch 408 a, 408 b is a single pole, double throw switch having a third“off” position sold by CW Industries of South Hampton, Pa.

In addition, circuit member 402 includes locating holes 422 at threeplaces which extend through the molded support body 400 and are createdby locating pins in the mold which remain in place during encapsulationand are removed after molding. The positions of locating holes 422 areoffset from one another and asymmetrical to prevent incorrectpositioning of the circuit member within the mold.

As is best seen in FIGS. 39-42, support body 400 is preferably molded toinclude a pair of recesses 424, 426 at opposite ends of the carriermember. Recesses 424, 426 are each defined by a contoured edge whichextends into the support body and around a respective set of bulbholders 406 a, 406 c, or 406 b, 406 d. When so positioned within therecesses 424, 426, each set of bulb holders extends at an angle to avertical line extending from top to bottom across the support body andalso to a line from the top to bottom of the mirror case when thecarrier member 310 is mounted therewithin. The support body is alsomolded to include a series of recesses 428 a, b, c, and d spaced alongits top edge and 430 a, b, c and d spaced along its bottom edge.Recesses 428 each have an inclined surface which faces upwardly andrearwardly when the support body and carrier member is mounted withinmirror housing/case 302. Recesses 430 each have an inclined surfacewhich faces downwardly and rearwardly when carrier member 310 ismounted, and are adapted to receive and mate with slots 330 on the lowerportions of interior walls 328 within the mirror case 302. Recesses 428and the inclined surfaces therein are adapted to engage and facilitatethe camming of the upper edge of the support body into the upper slots330 in the upper edge of internal walls 328 after the lower edge of thesupport body is placed in lower slots 330. Support body 460 isthereafter rotated rearwardly into the position shown in FIG. 46 duringsuch rotation, the inclined surfaces in recesses 428 engage with cammingsurfaces 332 and similar rounded surfaces on the upper ends of interiorwalls 360, 362. In addition, the lower edge of the support body includesa pair of spaced projections 432 which are immediately adjacent theinnermost recesses 430 b and 430 c and, therefore, abut interior walls328 b and 328 c when the carrier member is positioned within housing302. Projections 432 help to prevent lateral shifting of the carriermember within the case as aided by the engagement of recesses 428 and430 with the slots 330 in interior walls 328 and walls 360, 362.

As is best seen in FIGS. 39 and 40, support body 400 also includes aseries of spaced, outwardly projecting, interconnected ribs 434 on itsforwardly facing surface. Ribs 434 extend longitudinally along thesupport body surface, and adjacent and around recesses 424, 426. Ribs434 which strengthen, reinforce and rigidify the carrier member, reducemotion of the carrier member when plug connector 312 is inserted intothe plug connection of the mirror case, distribute load upon any impactreceived on the carrier member, and help restrict light leakage frombulbs 130 throughout the interior of the mirror housing/case 302. Inaddition, as shown in FIGS. 43, 45 and 46, ribs 434 help locate thecarrier member within the mirror case and prevent snap out afterassembly while helping to assure full and proper seating of theprismatic, reflective mirror element with the case. Specifically, in theevent carrier member 310 is not properly seated with recesses 428, 430in slots 330 in interior walls 328, mirror element 304 will not beproperly received within the case due to the projection of the ribs outof their normal position.

Support body 400 also includes downwardly extending rib sections 436 anda separate locating flange 438. Rib sections 436 are spaced from oneanother and from flange 438 to define switch receiving areas around thetwo sets of switch connections 412 a, 414 a, 416 a and 412 b, 414 b and416 b as described above. When mounted within the mirror housing/case302, ribs 434 and rib sections 436 and flange 438 extend forwardlytoward the rear surface of the mirror element 304. On the opposite orrear side of the support body 400 on carrier member 310 is a stopsurface or engagement area 440 adapted to be contacted by the lower edgeof spring bar 350 on toggle actuator 308 to position the actuator duringday/night movement of the mirror case as described above. Preferably,stop area 440 extends at a slight incline to the plane of the carriermember as shown in FIG. 43 for flush engagement with the toggleactuator. In addition, the rear surface of support body 400 alsoincludes a pair of spaced locating flanges 442 on either side of thearea from which plug connections 410 a, b and c extend outwardly.Flanges 442 help locate and position plug connector 312 when insertedinto the rear of the mirror assembly through recess 370 and opening 372.Also integrally molded with the carrier member support body are a pairof securing flanges or latch members 444 at the lower margin of the areasurrounding plug connections 410. Each latch member 444 includes anouter, terminal edge defining an undercut shoulder 446 providing a latchsurface adapted to engage a pivotable keeper 448 on plug connector 312.Keeper 448 includes a latch surface with an undercut shoulder 448 a atits inner end, and has an outer end 448 b adapted to be pressed withthumb or finger pressure toward connector 312 causing movement of innerend 448 a toward and away from connector 312 to allow engagement ordisengagement with latch members 444. Thus, when plug connector 312 isaligned with and telescoped over plug connections 410, shoulder 448 a onkeeper 448 is pivoted outwardly via end 448 b to receive securingflanges 444. Shoulder end 448 a engages shoulders 446 to prevent removalof the plug connector until end 448 b is again pressed downwardly towardthe plug connector to release the securing shoulder from the retainingshoulders 446 and securing flanges 444.

Preferably, carrier member 310 is an insert molded assembly like carriermember 20. Circuit member 402 is preformed and located by pins within asuitable mold cavity, while support body 400 is molded therearound topartially encase and/or encapsulate the circuit member within thesupport body such that the various electrical connections and bulbholders project from the support body. Like carrier 20, the preferredmaterial for support body 400 of carrier member 310 is amelt-processable, thermoplastic material such as nylon and preferably aglass and/or mineral-filled nylon such as 25 percent glass-filled nylonwhich is heat resistant, relatively rigid when formed andnon-electrically conductive such as Zytel™ available from E.I. DuPontNemours and Co. of Wilmington, Del. The preferred process is injectionmolding, although compression molding, extrusion molding, reactioninjection urethane molding, or casting of the support body about thecircuit member 402 can also be used. Like carrier member 20, circuitmember 402 is capable of carrying electricity of greater than one (1)amp such that the electricity is conducted and distributed from aconnection to an external electrical source to the various electricalcomponents on carrier member 310, such as lamps, switches, controls,instruments, or the like. Other variations in formation of the supportbody described above in connection with carrier member 20 may also beused with carrier member 310 including the incorporation of a receptaclefor connection of a PC circuit board for various alternative functionswithin the vehicle after mounting of the mirror assembly.

As shown in FIGS. 37 and 38, circuit member 402 may also include a pairof apertures 450 adapted to receive wire connectors from a diode 452soldered therein. Preferably, diode 452 (FIG. 37) is commerciallyavailable under trade number IN4004 having a voltage rating of 16 voltswhich reduces or prevents electrical current leakage from the circuitmember 402 to prevent battery drain when the mirror assembly 300 iselectrically connected to the electrical system of the vehicle in whichit is mounted via plug connector 312.

Referring now to FIGS. 32, 39, 40 and 42, the configuration and mountingof reflectors 314, 316 will be understood. Reflectors 314, 316 arepreferably molded from a high temperature resistant (i.e., greater than100° C. preferred), thermoplastic, melt-processable resinous, polymeric,plastic material, preferably a polyester material such as polybutyleneterephthalate (PBT), although other polymeric materials may also beused. Each reflector is substantially similar although including aslightly different shape depending on the area of the vehicle intendedto be illuminated. For references purposes, reflector 314 is described,although it should be understood that reflector 316 includessubstantially the same elements. Reflector 314 includes a curved,hollow, bulbous reflector body 460 having an integral mounting flange462 projecting upwardly from its top surface. Body 460 includes curvedwall portions 464 which extend from one end around the top surface tothe other end and a pair of opposed, generally parallel wall sections466, 468 forming truncated sides on opposed portions of the bulbousbody. Truncated walls 466, 468 are adapted to fit within the confinedspaced between mirror element 304 and rear wall 320 of case 302, andextend generally parallel to mirror element 304 when mounted in case302. The lower periphery 470 of the molded reflector lies in a plane anddefines a generally elongated profile. An aperture 474 extends throughcurved wall portions 464 to receive bulb 130 therethrough when mountedin bulb holders 406 (FIG. 39). Reflector 314 has a generally ellipticalprofile except for truncated wall portions 466, 468 so that light isdirected both downwardly and to one side of the mirror assembly forillumination of the lap or seat area of the passenger side of the frontseat of a vehicle. Reflector 316 directs light downwardly and toward thedriver lap or seat area of the vehicle front seat. Preferably, both theinner and outer surfaces of reflector 314, 316 are vacuum metalized, theinner surface having a high gloss to provide a highly specular, shinyreflective surface which efficiently directs light rays downwardly andin the intended directions from bulb 130.

As is best seen in FIGS. 39, 40 and 42, mounting flange 462 from eachreflector is fitted over a molded stud or post 476 extending outwardlyfrom the front surface of support body 400. Stud 376 is preferably sonicwelded or heat staked to retain flange 462 against the front surface ofthe carrier member, although suitable adhesives could also be used. Whenmounted in this manner on studs 476, reflectors 314, 316, respectively,are supported and engaged by the edges of recesses 426, 424,respectively, for secure retention and prevention of vibration of thereflector on the carrier member. This manner of attachment also allowsselection and interchangeability of the bulbous reflectors as desiredduring manufacture depending on the direction and location of the areato which the light from bulbs 130 is to be directed, for example toaccommodate left or right-hand drive vehicles. Preferably, bulbs 130,when mounted in bulb holders 406 project through apertures 474 such thatapproximately 4 millimeters of the bulb filament extends into the hollowinterior of the reflector.

Assembly of the modular rearview mirror assembly 300 will now beunderstood. A preassembled toggle actuator assembly including toggleactuator 308 and the desired type of mirror support arm and mountingbracket is inserted within the previously molded mirror case 302 byinserting the arm and bracket through opening 348 from the interior ofthe case toward the rear of the case. Toggle actuator 308 is then slideinto position such that pivot axle 342 is engaged with recesses orjournals 338 in wall 336. Pivot lever 356 projects through aperture 334during this operation. In addition, upper pivot axle 340 is inserted inthe journal recesses 339 at the top of the case. Next, carrier member310 is preassembled after molding to encapsulate circuit member 402therein by mounting reflectors 314, 316 over studs 476 and sonic weldingor heat staking the same to retain the reflectors in their supportedpositions against the edges of the recesses 424, 426. Thereafter, bulbs130 are inserted through apertures 474 into bulb holders 406 andelectrical switches 408 are telescoped onto the electrical connectionson the front side of the carrier member.

Following preparation of the modular carrier member 310 as describedabove, that subassembly is inserted within the housing/case 302 byplacing the lower edge of the carrier member into the slots 330 ininterior walls 328 such that plungers 409 and caps 415 on switches 408extend through apertures 368. Thereafter, the top edge of the carriermember is rotated through front opening 326 toward the rear of the casesuch that the inclined surfaces of recesses 428 engage wall surfaces 332following which further pressure snaps the carrier member into place inthe slots 330 at the top of walls 328, as shown in FIG. 46.

All of the above is preferably accomplished by preassembling the carriermembers 310 prior to molding of the case 302. The toggle actuator 308and preassembled carrier member 310 are assembled within the caseshortly after the case is removed from its mold and while the casematerial is still warm and somewhat flexible. Following insertion of thecarrier member, the prismatic mirror element 304 including resilientbacking 306 is inserted into the case by dropping its lower edge intothe area behind lip 324 and again rotating the upper edge toward therear of the case with pressure such that the mirror element snapsthrough the front opening 326 into the position shown in FIGS. 43-46.Thereafter, lenses 380 may be snapped in place in openings 318 and themirror assembly is ready for installation. Once installed on a vehicle,plug connector 312 need only be inserted through recess 370 and opening372 until keeper 448 engages latch members 444 to hold the plugconnector in place over electrical connectors 410. Thereafter, thetoggle actuator may be operated by lever 356 to rotate the mirrorassembly between day and night positions, as shown in FIG. 43 to reflectvarying amounts of reflected light to the eye of the viewer as desired.

Preferably, plug connector 312 establishes electrical connections to thevehicle electrical system such that lamp bulbs 130 will operate inresponse to switches 408 either when a vehicle occupant desires light orwhen a door of the vehicle is opened. Hence, switches 408 a, 408 b,which each control one of the bulbs 130, may be operated via plungers409 a, 409 b to illuminate continuously, or only when a door is opened,or not at all.

It is also possible to incorporate low level console or instrumentationlighting for vehicles in assemblies 10, 150, 170, 270, or 300 by fittinga low level, non-incandescent, light emitting light source such as alight emitting diode on any of carrier members 20, 20′, 190, 20″, or 310for illumination through openings in cases, 12, 12′, 172, 272, or 302 asdisclosed in commonly-assigned U.S. patent application Ser. No.08/367,844, filed Dec. 30, 1994, by Brent J. Bos et al., now U.S. Pat.No. 5,671,996, the disclosure of which is hereby incorporated byreference herein.

The concepts of this present invention may be used in a variety ofautomotive rearview mirror assemblies. Referring to FIG. 47, in a sixthembodiment, modular rearview mirror assembly 500 includes a mirror case502, with a bezel 501 and reflector 504 supported therein, and a pod 506both of which are mounted to a window button 500 a adhered to windshieldW by a mirror mount 526. Mirror assembly 500 may optionally include asupport 502 a, including a fixed or movable support, for mounting case502 to mirror mount 526. As will be more fully described below, mirrorassembly 500 may also include one or more of a plurality of electricaland/or electronic components mounted in or on any one of the componentsof mirror assembly 500, including case 502, bezel 501, pod 506, min ormount 526, windshield button 500 a, support 502 a, and/or carrier memberor circuit board 510, and the like. For example, the present inventionmay include those assemblies described in U.S. patent application Ser.No. 08/799,734, entitled “Vehicle Blind Spot Detection and DisplaySystem”, invented by Schofield et al. and filed Feb. 12, 1997, now U.S.Pat. No. 5,786,772, the disclosure of which is hereby incorporatedherein by reference. A blind spot detection indicator 503 may bepositioned in reflector 504. Furthermore, mirror assembly 500 mayinclude a rain sensor 505 mounted, for example, in pod 506. Rain sensorfunctionality, as is commonly known in the automotive art, is providedin association with an interior rearview mirror assembly. Suchassociation includes utilizing an element of the rearview mirrorassembly (such as a plastic housing attached, for example, to the mirrorchannel mount that conventionally attaches the mirror assembly to awindshield button) to cover a windshield-contacting rain sensor (such asis described in U.S. Pat. No. 4,973,844 entitled “Vehicular MoistureSensor and Mounting Apparatus Therefor”, invented by O'Farrell et al.and issued Nov. 27, 1990, the disclosure of which is hereby incorporatedherein by reference), or it may include a non-windshield-contacting rainsensor (such as is described in PCT International ApplicationPCT/US94/05093 entitled “Multi-Function Light Sensor For Vehicle”invented by Dennis J. Hegyi, published as WO 94/27262 on Nov. 24, 1994,the disclosure of which is hereby incorporated by reference herein).Also, a mirror mounted video camera can be used to visually detect thepresence of moisture on the windshield, and actuate the windshieldwipers accordingly, such as is described in U.S. patent application Ser.No. 08/621,863, filed Mar. 25, 1996, entitled VEHICLE HEADLIGHT CONTROLUSING IMAGING SENSOR, by Schofield et al., now U.S. Pat. No. 5,796,094,which is hereby incorporated by reference herein.

Modular rearview mirror assembly 500 may also include one or moredisplays 507 which may be mounted on one or more of the assemblycomponents as noted above. Displays 507 may perform a single displayfunction or multiple display functions, such as providing indication ofan additional vehicle function, for example a compass mirror displayfunction, a temperature display function, status of inflation of tiresdisplay function, a passenger air bag disable display function, anautomatic rain sensor operation display function, telephone dialinformation display function, highway status information displayfunction, blind spot indicator display function, or the like. Suchdisplay may be an alpha-numerical display or a multi-pixel display, andmay be fixed or scrolling. Such an automatic rain sensor operationdisplay function may include a display function related to rain sensor505 for both a windshield-contacting and a non-windshield-contactingrain sensor, including, for example, where the circuitry to control rainsensor 505 and other electrical and/or electronic devices, includingelectrochromic dimming circuitry 504 a of a variable reflectanceelectrochromic mirror, bulb holders, and switches, are commonly housedin or on rearview mirror assembly 500 and wholly or partially sharecomponents on common carrier member or circuit board 510. Circuit board510 may be of the type described in the present invention, such as acarrier member 310 incorporating a circuit member 402. Display 507 mayalternate between display functions by a display toggle which may bemanually operated, time-shared, voice-actuated, or under the control ofsome other sensed function, such as a change in direction of the vehicleor the like. Should a rain sensor control circuitry 505 a be associatedwith, incorporated in, or coupled to interior rearview mirror assembly500, rain sensor control circuitry 505 a, in addition to providingautomatic or semi-automatic control over operation of the windshieldwipers (on the front and/or rear windshield of the vehicle), may beadapted to control the defogger function to defog condensed vapor on aninner cabin surface of a vehicle glazing (such as the inside surface ofthe front windshield, such as by operating a blower fan, heaterfunction, air conditioning function, or the like), or rain sensorcontrol circuitry 505 a may be coupled to a sunroof to close the sunroofor any other movable glazing should rain conditions be detected.

As stated above, it may be advantageous for the rain sensor controlcircuitry 505 a (or any other feature such as a head-lamp controller, aremote keyless entry receiver, a cellular phone including itsmicrophone, a vehicle status indicator and the like) to share componentsand circuitry with other components and/or control circuitry, forexample with an electrochromic mirror function control circuitry and anelectrochromic mirror assembly itself. Also, a convenient way to mount anon-windshield-contacting rain sensor such as described by Hegyi is byattachment, such as by snap-on attachment, as a module to the mirrorchannel mount such as is described in U.S. Pat. No. 5,576,687 entitled“Mirror Support Bracket,” invented by R. Hook et al. and issued Nov. 19,1996, the disclosure of which is hereby incorporated by referenceherein. The mirror mount and/or windshield button may optionally bespecially adapted to accommodate a non-windshield-mounting rain sensormodule. Such mounting as a module is readily serviceable and attachableto a wide variety of lighted and unlighted interior mirror assemblies(both electrochromic and non-electrochromic such as prismatic, manuallyadjusted mirror assemblies), and can help ensure appropriate alignmentof the non-windshield-mounted variety of rain sensor to the vehiclewindshield insofar that the module attached to the mirror mount remainsfixed whereas the mirror itself (which typically attaches to the mirrorchannel mount via a single or double ball joint support) is movable sothat the driver can adjust its field of view. Also, should smoke fromcigarettes and the like be a potential source of interference to theoperation of the non-windshield-contacting rain sensor, then aminor-attached housing can be used to shroud the rain sensor unit andshield it from smoke (and other debris). Optionally, such ability todetect presence of cigarette-smoke can be used to enforce a non-smokingban in vehicles, such as is commonly requested by rental car fleetoperators. Also, when a rain sensor (contacting or non-contacting) isused to activate the wiper on the rear window (rear blacklight) of thevehicle, the rain sensor may be alternatively packaged and mounted withthe CHMSL (center high mounted stop light) stop light assembly commonlymounted on the rear window glass or close to it. Mounting of the rainsensor with the CHMSL stop light can be aesthetically appealing andallow sharing of components/wiring/circuitry.

As mentioned above, the concepts of this present invention can be usedwith interior rearview mirrors equipped with a variety of features, suchas a home access transmitter 508 a, a high/low (or daylight runningbeam/low) headlamp controller 508 b, a hands-free phone attachment 508c, a video device 508 d, such as a video camera, for internal cabinsurveillance and/or video telephone function, a remote keyless entryreceiver 508 e, a compass 508 f, a seat occupancy detection 508 g, oneor more map reading lights 508 h, or lamps/bulbs 130 described above, atrip computer 508 i, an intrusion detector 508 j, and the like. Display507 may also include a compass/temperature and/or clock display, fuellevel display, and other vehicle status and other information displays.Again, such features can share components and circuitry with, forexample, electrochromic mirror circuitry 504 a and other components ofassembly 500 so that provision of these extra features is economical.

Placement of video device 508 d (FIG. 47) either at, within, or on theinterior rearview mirror assembly (including within or on a moduleattached to a mirror structure such as the mount that attaches to thewindshield button) has numerous advantages. In the illustratedembodiment, video device 508 d is located in case 502 and positionedbelow reflective element 504. For example, locating video device 508 din rearview mirror assembly 500 provides the video device 508 d with anexcellent field of view of the driver and of the interior cabin ingeneral since the rearview mirror is centrally and high mounted. Also,mirror assembly 500 is at a defined distance from the driver so thatfocus of the video device is facilitated. Also, if video device 508 d isplaced on a movable portion of mirror assembly 500, for example case502, the normal alignment of mirror reflector 504 relative to thedriver's field of vision rearward can be used to readily align the videodevice 508 d to view the head of the driver. Since many interiorrearview mirrors, such as the lighted mirrors of the present invention,are electrically serviced, placement of video device 508 d at, within,or on the rearview minor assembly can be conventionally and economicallyrealized, with common sharing of components and circuitry by, forexample, compass 508 f (which may include a flux gate sensor, amagneto-resistive sensor, a magneto-inductive sensor, or amagneto-capacitive sensor), a bulb holder for light 508 h or bulbs 130,switches, an electrical distribution busbar such as circuit member 402,a display, such as display 507, and electrochromic dimming mirrorcircuitry 504 a. Although the driver is likely the principal target andbeneficiary of video device 508 d, the lens of video device 508 d can bemechanically or electrically (i.e., via a joystick) adjusted to viewother portions/occupants of the vehicle cabin interior. In this regard,the joystick controller that adjusts the position of the reflector onthe outside rearview mirrors can, optionally, be used to adjust thevideo device field of view as well. Preferably, video device 508 d isfixedly mounted in the mirror case 502, for example on carrier member510 and connected to a circuit member such as 402 with the lens of videodevice 508 d positioned for viewing through bezel 501. Alternately,video device 508 d maybe mounted in a gondola typeprotrusion/attachment/module below the mirror housing (but mechanicallyattached thereto so the camera field of vision moves in tandem withmovement of the minor housing). Alternately, video device 508 d may bemounted in pod 506 attached to the mirror mount 526 or on windshieldbutton 500 a (with the camera lens facing rearward in the vehicle andgenerally facing the driver). Video device 508 d may comprise a CCDcamera or a CMOS based video microchip camera, such as is described incommonly owned U.S. patent application Ser. No. PCT/US94/01954, filedFeb. 25, 1994, published Sep. 1, 1994, as WO 94/19212, the disclosure ofwhich is hereby incorporated by reference herein. For operation atnight, the internal cabin of the vehicle may optionally be illuminatedwith non-visible radiation, such as near-infrared radiation, with videodevice 508 d being responsive to the near-infrared radiation so that avideo telephone call can be conducted even when the interior cabin isdark to visible light, such as at night.

Also, video device 508 d, which is preferably mounted at, within, or onthe inner rearview mirror assembly (such as within the mirror case 502or in pod 506, which is attached to mirror mount 526), may be adapted tocapture an image of the face of a potential driver and then, usingappropriate image recognition software, decide whether the driver isauthorized to operate the vehicle and, only then, enable the ignitionsystem to allow the motor of the vehicle be started. Use of such amirror-mounted video device (or a digital still camera) enhances vehiclesecurity and reduces theft. Further, video device 508 d may be adaptedto monitor the driver while he/she is driving and, by detection of headdroop, eye closure, eye pupil change, or the like, determine whether thedriver is becoming drowsy/falling asleep, and then to activate a warningto the driver to stay alert/wake up.

It is beneficial to use a microprocessor to control multiple functionswithin the interior mirror assembly and/or within other areas of thevehicle (such as the header console area), and such as is described inIrish Patent Application No. 970014, entitled “A Vehicle Rearview Mirrorand A Vehicle Control System Incorporating Such Mirror,” filed Jan. 9,1997, published Jul. 15, 1998, the disclosure of which is herebyincorporated by reference herein. Such microprocessor can, for example,control the electrochromic dimming function, a compass directiondisplay, an external temperature display, and the like. For example, auser actuatable switch can be provided that at one push turns on acompass/temperature display, on second push changes the temperaturedisplay to metric units (i.e., to degrees Celsius), on third pushchanges to Imperial units (i.e., degrees Fahrenheit) and on fourth pushturns off the compass/temperature display, with the microprocessorcontrolling the logic of the display. Alternately, a single switchactuation turns on the display in Imperial units, the second actuationchanges it to metric units, and third actuation turns the display off.Further, the displays and functions described herein can find utilityalso on outside rearview mirrors. For example, a transducer 508 k thatreceives and/or transmits information to a component of an intelligenthighway system (such as is known in the automotive art) can beincorporated into an interior and/or outside rearview mirror assemblyand, preferably, mounted to common circuit board or carrier member 510.Thus, for example, a transmitter/receiver 5081 for automatic toll boothfunction could be mounted at/within/on an outside sideview mirrorassembly. Preferably, transmitter/receiver 5081 is also mounted tocommon circuit board or carrier member 510. A digital display of thetoll booth transaction can be displayed by display 507. Optionally, amicro printer 509 may be incorporated within rearview mirror assembly500 which can print a receipt or record of the transaction. In theillustrated embodiment, printer 509 is shown mounted in case 502, but itshould be understood, as with most of the other components, that it canbe mounted in a variety of locations on mirror assembly 500. Similarly,for safety and security on the highways, GPS information, state oftraffic information, weather information, telephone number information,and the like may be displayed and transmitted/received via transducerslocated at, within, or on an interior rearview mirror assembly and/or anoutside sideview mirror assembly.

Also, interior rearview mirror assembly 500 may optionally include anInternet Interface circuit 511 to provide a link to the Worldwide Web.Circuit 511 may be coupled to a modem/cellular phone or cell phonecontrol panel 512 mounted within the vehicle, and preferably, mountedat, within or on the interior rearview mirror assembly 500. Thus, thedriver or passenger can interact with other road users, canreceive/transmit messages including E-mail, can receive weather andstatus of highway traffic/conditions, and the like, via a mirror locatedinterface to the INTERNET.

Further, a trainable garage door opener 513, including a universalgarage door opener such as is available from Prince Corporation,Holland, Mich. under the tradename HOMELINK™, or a transmitter 514 for auniversal home access system that replaces the switch in a householdgarage that opens/closes the garage door with a smart switch that isprogrammable to a household specific code that is of the rolling codetype, such as is available from TRW Automotive, Farmington Hills, Mich.under the tradename KWIKLINK™, may be mounted at, within, or on interiormirror assembly 500 (or, if desired, an outside sideview mirror).Switches to operate such devices (typically up to three separate pushtype switches, each for a different garage door/security gate/householddoor) can be mounted on mirror assembly 500, preferably user actuatablefrom the front face of the mirror case 502 or pod 506. Preferably, theuniversal garage door opener HOMELINK™ it or the universal home accessKWIKLINK™ unit is mounted at, within, or on interior rearview mirrorassembly 500. Optionally, such a unit could be mounted at, within or onan outside sideview mirror assembly.

The KWIKLINK™ Universal Home Access System (which operates on a rollingcode, such as is commonly known in the home/vehicle security art)comprises a vehicle mounted transmitter and a receiver located in thegarage. The KWIKLINK™ system is a low-current device that can be,optionally, operated off a battery source, such as a long life lithiumbattery. It is also compact and lightweight as executed on a single- ordouble-sided printed circuit board.

The KWIKLINK™ printed circuit board can be mounted within the mirrorhousing (optionally adhered to a shock absorber comprising adouble-sticky tape anti-scatter layer on the rear of the reflectorelement (prismatic or electrochromic) such as is described in U.S. Pat.No. 5,572,354 entitled “Rear Mirror Assembly”, invented by J. Desmond etal. and issued Nov. 5, 1996, the disclosure of which is herebyincorporated by reference herein or may be accommodated within pod 506,such as the detachable pod module described in U.S. Pat. No. 5,576,687entitled “Mirror Support Bracket”, invented by R. Hook et al. and issuedNov. 19, 1996, the disclosure of which is hereby incorporated byreference herein, and with the detachable module attached to the mirrormount or to the mirror button. Mounting the KWIKLINK™ unit in adetachable module has advantages, particularly for aftermarket supplywhere a battery operated KWIKLINK™ unit can be supplied within a podhousing (with the necessary user actuatable button or buttons mounted onthe pod and with the battery being readily serviceable either by accessthrough a trap door and/or by detaching the pod from the mirror mount).By supplying a battery-operated, stand-alone, snap-on, detachableKWIKLINK™ mirror mount pod, the KWIKLINK™ home access system can bereadily and economically provided to a broad range of mirrors includingnon-electrical mirrors such as base prismatic mirrors, and electricalmirrors such as unlighted and lighted mirrors (including prismatic andelectrochromic types) and electro-optic mirrors, such as electrochromicmirrors. Further, a solar panel 514 a may be installed on the podhousing to recharge the battery.

Also, pod 506 may have a windshield button mount attached thereto orincorporated therein and have, in addition, a structure that replicatesthe windshield button standard on most vehicles manufactured in theUnited States. Thus, when a consumer purchases such an aftermarketproduct, the consumer simply removes the existing interior rearviewmirror assembly from the windshield button it is attached to in thevehicle. Then, the consumer attaches a pod module windshield buttonmount of the type shown in U.S. Pat. No. 4,930,742, the disclosure ofwhich is hereby incorporated by reference herein, to the windshieldbutton attached to the windshield (this can be achieved either bysliding on and securing with a screwdriver, or by snap-on in a mannerconventional in the mirror mounting art). Finally, the consumer nowattaches the rearview mirror assembly to the windshield buttonreplication structure that is part of the aftermarket pod module. Sincethe windshield button shape is largely an industry standard (but theinterior rearview mirror mount that attaches thereto is typically notstandard), by using this “button on a button” pod module design, anaftermarket product (such as a pod module incorporating one or moreelectrical and/or electronic devices, including the home accesstransmitter, universal garage door opener, security monitor such as apyroelectric intrusion detector (such as disclosed in U.S. patentapplication Ser. No. 08/720,237 filed Sep. 26, 1996, the disclosure ofwhich is hereby incorporated by reference herein), remote keyless entryreceiver, and compass, as described previously, and the like, may bereadily installed by the vehicle owner, and the existing rearview mirrorassembly can be readily remounted in the vehicle.

Interior mirror assembly 500 may further include a cellular phone 515incorporated into interior mirror assembly 500 with its antenna,optionally, incorporated into the outside sideview mirror assembly orinto inside rearview mirror assembly 500. Such mounting within themirror assemblies has several advantages including that of largelyhiding the cellular phone and antenna from ready view by a potentialthief. Furthermore, seat occupancy detector 508 g may be coupled to anair bag deployment/disable monitor, which can be located at, within oron the interior rearview mirror assembly 500. Seat occupancy detector508 g may comprise a video microchip or CCD camera seat occupancydetector, an ultrasonic detector, a pyroelectric detector, or anyone ormore of their combination. Moreover, where more than one rearview mirroris being controlled or operated, or when several vehicle accessories arelinked to, for example, an electrochromic interior or outside mirror,interconnections can be multiplexed, as is commonly known in theautomotive art. Moreover, where it is desired to display externaloutdoor temperature within the interior cabin of the vehicle, atemperature sensor (such as a thermocouple or thermistor) can be mountedat, within or on an outside sideview mirror assembly (for example, itcan protrude into the slipstream below the lower portion of the sideviewmirror housing in a manner that is aesthetically and styling acceptableto the automakers and to the consumer) and with the temperature sensoroutput connected, directly or by multiplexing to display 507 or aseparate display (such as a vacuum fluorescent display) located in theinterior cabin of the vehicle.

Preferably, the external temperature display is located at, within or onthe interior rearview mirror assembly, optionally in combination withanother display function such as a compass display (see U.S. patentapplication Ser. No. 08/799,734, entitled “Vehicle Blind Spot DetectionSystem” invented by K. Schofield et al., and filed Feb. 12, 1997, nowU.S. Pat. No. 5,786,772), or as a stand-alone pod such as pod 506 as amodule to a mirror support member (see U.S. Pat. No. 5,576,687). Mostpreferably, the interior and outside mirror assemblies are supplied bythe same supplier, using just-in-time sequencing methods, such as iscommonly known in the automotive supply art and as is commonly used suchas for supply of seats to vehicles. Just-in-time and/or sequencingtechniques can be used to supply a specific option (for example, theoption of configuring an external temperature display with a baseprismatic interior mirror, or with a base electrochromic interiormirror, or with a compass prismatic interior mirror, or with a compasselectrochromic interior mirror) for an individual vehicle as it passesdown the vehicle assembly line. Thus, the automaker can offer a widearray of options to a consumer from an option menu. Should a specificcustomer select an external temperature display for a particular vehicledue to be manufactured by an automaker at a particular location on aspecific day/hour, then the mirror system supplier sends to the vehicleassembly plant, in-sequence and/or just-in-time, a set of an interiorrearview mirror assembly and at least one outside sideview mirrorassembly for that particular vehicle being produced that day on theassembly line, and with the outside sideview mirror equipped with anexternal temperature sensor and with the interior rearview mirrorassembly equipped with an external temperature display. Suchjust-in-time, in-sequence supply (which can be used for theincorporation of the various added features recited herein) isfacilitated when the vehicle utilized a car area network such as isdescribed in Irish Patent Application No. 970014 entitled “A VehicleRearview Mirror and A Vehicle Control System Incorporating Such Mirror”,application date Jan. 9, 1997, the disclosure of which is herebyincorporated by reference herein, or when multiplexing is used, such asis disclosed in U.S. patent application Ser. No. 08/679,681 entitled“Vehicle Mirror Digital Network and Dynamically Interactive MirrorSystem”, invented by O'Farrell et al., and filed Jul. 11, 1996, now U.S.Pat. No. 5,798,575, the disclosure of which is hereby incorporated byreference herein. Also, given that an interior electrochromic mirror canoptionally be equipped with a myriad of features (such as map lights,reverse inhibit line, headlamp activation, external temperature display,remote keyless entry control, seat occupancy detector such as byultrasonic, pyroelectric or infrared detection, and the like), it isuseful to equip such assemblies with a standard connector (for example,a 10-pin parallel connector) such as electrical connections 410 forreceiving a plug connector 312 as described above, so that a commonstandard wiring harness can be provided across an automaker's entireproduct range. Naturally, multiplexing within the vehicle can helpalleviate the need for more pins on such a connector, or allow a givenpin or set of pins control more than one function.

The concepts of this present invention can be further utilized in addedfeature interior rearview mirror assemblies including those that includea loudspeaker (such as for a vehicle audio system, radio or the like, orfor a cellular phone including a video cellular phone). Such loudspeakermay be a high frequency speaker that is mounted at, within, or on theinterior rearview mirror assembly 500 (such as within the mirror case502 or attached as a module-type pod to the mirror mount such as isdescribed above and as shown as loudspeaker 517 in FIG. 47) and with itsaudio output, preferably, directed towards the front windshield of thevehicle so that the windshield itself at least partially reflects theaudio output of the speaker (that preferably is a tweeter speaker, morepreferably is a compact (such as about 1″×1″×1″ in dimensions orsmaller), and most preferably utilizes a neodymium magnet core) backinto the interior cabin of the vehicle. Interior rearview mirrorassembly 500 may also include a microphone 518 and a digital (or aconventional magnetic tape) recorder 519 with its associated circuitry519 a, which can be used by vehicle occupants to record messages and thelike. Display 507 may be adapted to receive paging information from apager 521, which may be incorporated in interior rearview mirrorassembly 500, for example, in pod 506, and that displays messages to thedriver (preferably via a scrolling display) or to other occupants.Interior rearview mirror assembly 500 may include a digital storagedevice 522, which stores information such as phone numbers, messagereminders, calendar information, and the like, that can, automaticallyor on demand, display information to the driver.

The concepts of this present invention can be utilized in a variety ofprismatic and electrochromic compass mirrors (both lighted and unlightedmirrors) that display directional information based upon compass sensor508 f (which may comprise a flux gate sensor, a magneto-responsivesensor, such as an magneto-resistive sensor, magneto-inductive sensor,or a magneto-capacitive sensor, a hall affect sensor, or an equivalentcompass sensor). Alternatively, directional information obtained from ageographic positioning system such as a Global Positioning System (GPS)as is disclosed in U.S. patent application Ser. No. 08/569,851, filedDec. 8, 1995, entitled VEHICLE GLOBAL POSITIONING SYSTEM, by O'Farrellet al, now U.S. Pat. No. 5,971,552, the disclosure of which is herebyincorporated by reference herein, could be used to provide the compassdirection signal for a mirror mounted display. For instance, a mirror ofthis invention could utilize as a variable reflective element with anelectrochromic solid polymer matrix such as described in commonlyassigned U.S. patent application Ser. No. 08/824,501, filed on Mar. 27,1997, now U.S. Pat. No. 5,910,854, the disclosure of which is herebyincorporated by reference. Compass sensor 508 f may be mounted anywherein the vehicle and with its directional signal fed to a digital display,for example display 507, (such as a liquid crystal display, a vacuumfluorescent display, or light emitting diode display, an electroluminescent display, or the like) that is mounted at/in/on interiorrearview mirror assembly 500. In another example, compass sensor 508 fmay be mounted in the dashboard or in the header region close to theroof of the vehicle. Compass sensor 508 f may also be mounted atinterior rearview mirror assembly 500 by placement within pod 506 thatfixedly mounts sensor 508 f to mirror assembly support 526, whichattaches interior minor assembly 500 to windshield button mount 500 a,and as is described in U.S. Pat. No. 5,530,240 to Larson et al. and inU.S. Pat. No. 5,576,687 entitled “Mirror Support Bracket”, referred toabove. In the illustrated embodiment, however, compass sensor 508 f ismounted within case 502 of interior mirror assembly 500 along with itsassociated circuitry and any optional map lights (508 h) and the like.Mounting of compass sensor 508 f within the housing of the interiormirror assembly (as an alternate to placing the compass within pod 506,which may be fixedly attached to mirror support that typically attachesto the front windshield and bracket) has some advantages. For example,by mounting compass sensor 508 f within case 502, pod 506 may beeliminated along with the wire harness, which would be required tocouple the compass directional signals from sensor 508 f in pod 506 todisplay 507, which is preferably mounted within case 502. Such locationof compass sensor 508 f within or at case 502 of mirror assembly 500also means that there is no external evidence of the presence of thesensor, and, thus, aesthetics are potentially enhanced. Also, suchplacement of sensor 508 f within case 502 of mirror assembly 500 (suchas schematically shown in FIG. 47) is suitable for header mountedmirrors such as shown in U.S. Pat. No. 5,615,857, the reference to whichherein incorporated by reference in its entirety. Most preferably,sensor 508 f is in the form of an integrated circuit chip mount (orsimilar printed circuit board insertable form) so that compass sensor508 f can be placed on circuit board 510 as are preferably the otherelectrical/electronic components within case 502 of interior mirrorassembly 500. By having compass sensor 508 f housed within the rearviewmirror assembly 500 along with it wholly or partially sharingcomponents, manufacturing and packaging economies are realized. Suchhousing of compass sensor 508 f on common printed circuit board orcircuit member 510 along with the other electrical and/or electroniccomponents, for example, any one or more electrical or electroniccomponents described in reference to this and earlier embodiments,including any electrochromic dimming circuitry to automatically dimreflectivity when glare conditions are detected by light sensors,displays, any bulb holders/switches, microprocessors, and their like,further enhances the manufacturing and packaging economies. Since case502 of mirror assembly 500 is adjustable by the driver to assist his orher needs, a compass sensor 508 f within case 502 may have a differentorientation from one driver to another, which may result in a relativelyminor inaccuracy in directional information. These inaccuracies,however, are typically unnoticeable and, moreover, may be mitigated byusing stabilization means and algorithms, including fuzzy logic, and/orusing deviation compensatory means, as are known in the compass art.

Further, where compass and compass/temperature displays such as shown inU.S. Pat. No. 5,786,772, are used, the front plate over the display maybe angled relative to the driver's line of sight (between about 2° to10° and, most preferably, between about 4° to 8° relative to line ofsight), so that any headlight glare incident thereon is reflected awayfrom the driver.

While several forms of the invention have been shown and described,other forms will now be apparent to those skilled in the art. Therefore,it will be understood that the embodiments shown in the drawings anddescribed above are merely for illustrative purposes, and are notintended to limit the scope of the invention which is defined by claimswhich follow.

1. A rearview mirror assembly for vehicles comprising: a case having areflective mirror element, said case including at least one openingtherethrough; a support on said assembly for mounting said assembly on avehicle; a modular carrier member formed separately from and mounted tosaid case, said carrier member including an electrically conductivecircuit member and a non-electrically conducting support body, saidcircuit member being formed separately from and secured to said supportbody, said carrier member providing an integral support, electricalconnections for, and an electrical distribution network to at least onelamp on said case; and a lamp mounted on said carrier member, connectedto said circuit member, and adapted to provide light through said caseopening to a portion of the vehicle when said mirror assembly is mountedthereon; said carrier member including an edge portion defining arecess, said circuit member including a bulb holder within said recess,and a reflector secured to said carrier member and received in saidrecess, said recess edge portion engaging and supporting said reflector,said lamp including a bulb mounted within said recess in said bulbholder, said reflector reflecting light from said bulb through said caseopening when said bulb is illuminated.